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TO 19-75AA-67

DEPXITMENT OF THE AIIMr TECHNICAL MANUAL

ORDNANCE MAINTENANCE

ENGINE

(WILLYS-OVERLAND

MODEL MC)

AND CLUTCH

FOR 1/4 TON

4x4 UTILITY TRUCK

M38

DEPARTMENT OF THE ARMY • JUNE 1951

This CD produced by

Military Media, Inc

CONTENTS

CHAPTER 1. INTRODUCTION PanigrapA* Page,

Section /. General____- 1-3 1-2

/J. Description and data 4-5 3

CHAPTER 8. PARTS, SPECIAL TOOLS, AND EQUIPMENT

FOR RELD AND DEPOT MAINTENANCE e-8 8

CHAPTER 3. TROUBLE SHOOTING

Section 7. General 9-10 U

//. Engine -- 11-12 12

CHAPTER 4. ENGINE

Section J. Description and data 13-18 15-16

//. Power plant removal from vehicle 19-20 16-17

///. Preparation of engine for rebuild. -. 21-30 30-40

IV, Disassembly of stripped engine into subassemblies 31-41 43-52

V. Rebuild of cylinder block, head, and oil pan 42-43 53

V/. Rebuild of water pump 44-47 68-59

VTL Rebuild of connecting rods and pistons 48-53 62-7 1

VIIL Rebuild of camshaft. 64r-55 71-72

IX. Rebuild of valve and valve springs 56-59 73

X. Rebuild of valve tappets 60-63 74

XI. Rebuild of oil pump and oil strainer _ 64^67 76-78

XII. Rebuild of crankshaft 68-69 81

XIII. RebuUd of flywheel 70-74 82-83

XIV, Rebuild of intake and exhaust manifolds 75-78 83-84

X V. Assembly of engine from subassemblies 79-93 85-96

XVI. Installation of accessories 94^103 96-^8

XVII. Run-in tests and adjustments 104^106 98

XVni. Assembly of power plant 107-126 100

CHAPTER 5. CLUTCH

Section I. Description and data 127-128 104

//. Disassembly of pressure plate 129-131 104

///. Assembly of pressure plate 132-134 107

CHAPTER 6. ENGINE VENTILATION FOR DEEP WATER
FORDING OPERATION

Section I. Description and data 135-141 109-110

II. Inspection and repair of engine ventilation system 142-143 110-111

///. Test of internal crankcase pressure - 144-147 111-112

CHAPTER 7. SERVICEAilLITY STANDARDS 148-167 121 -128

APPENDIX, REFERENCES 129

INDEX - - 1^2

CHAPTER 1
INTRODUCTION

Section i. GENERAL

1. Scope

flf. This manual is published for the information and guidance of
personnel responsible for depot maintenance of this materiel. It con-
tains information on maintenance which is beyond the scope of the
tools, equipment, or supplies normally available to using organizations.
This manual does not contain information which is intended pri-
marily for the using organization, since such information is available
to ordnance maintenance personnel in the pertinent operator's techni-
cal manuals or field manuals.

b. This manual contains a description of and procedures for re-
moval, disassembly, inspection, repair, rebuild, and assembly of the
engine and clutch for the %-ton 4x4 utility truck M38, The appendix
contains a list of current references, including supply catalogs, techni-
cal manuals, and other available publications applicable to the
materiel.

e, TM 9-804 contains operating and lubricating instructions for the
materiel and contains all maintenance operations allocated to using
organizations in performing maintenance work within their scope.

d, TM 9-1804B contains service information on the power train,
body and frame.

e, TM 9-1825A or TM 9-1825B contains service information on the
Delco-Eemy or Auto-Lite electrical equipment.

/. TM 9-1826A contains service information on the Carter carbu-
retor.

g, TM 9-1828 A contains service information on the AC fuel pump.

A. This first edition manual is being published in advance of com-
plete technical review of all concerned. Any errors or omissions
will be brought to the attention of Chief of Ordnance, Washington
26, D. C, ATTENTION : ORDFM-Pub.

2. Field and Depot Maintenance Allocation

The publication of instructions for complete disassembly and re-
build is not to be construed as authority for the performance by field

maintenance units of those functions which are restricted to depots
and arsenals. In general, the prescribed maintenance responsibilities
are based upon availability of tools, parts, and trained personnel and
will apply as reflected in the allocation of maintenance parts listed in
the appropriate columns of the current ORD 8 supply catalog per-
taining to the %-ton 4x4 utility truck M38. Instructions for depot
maintenance are to be used by maintenance companies in the field
only when the tactical situation makes the repair functions imperative.
Provisions of parts listed in the depot stock guide column of ORD 8
supply catalogs will be made to field maintenance units only when the
emergency nature of the maintenance to be performed has been certi-
fied by a responsible officer of the requisitioning organization. Those
operations which can be performed as "emergency field maintenance"
are specifically covered in this manual.

3. Forms, Records, and Reports

a. General. Forms, records, and reports are designed to serve
necessary and useful purposes. Responsibilities for the proper execu-
tion of these forms rests upon commanding officers of all units main-
taining this equipment. It is emphasized, however, that forms,
records, and reports are merely aids. They are not a substitute for
thorough practical work, physical inspection, and active supervision.

h. Authorized Forms. The forms generally applicable to units
maintaining this equipment are listed in the appendix. No forms
other than those approved for the Department of the Army will be
used. For a current and complete listing of all forms, see SR 310-
20-6. Additional forms applicable to the using personnel are listed
in the operator's manual. For instructions on use of these forms,
refer to FM 9-10.

(?. Field Report or Accidents. The reports necessary to comply
with the requirements of the Army safety program are prescribed in
detail in the SR 385-10-40 series of special regulations. These reports
are required whenever accidents involving injury to personnel or dam-
age to materiel occur.

d. Reiport of Unsatiseactory Equipment or Materials. Any
suggestions for improvement in design and maintenance of equip-
ment, safety and efficiency of operation, or pertaining to the applica-
tion or effect of prescribed petroleum fuel, lubricants, and/or
preserving materials, will be reported through technical channels, as
prescribed in SR 700-^5-5, to the Chief of Ordnance, Washington 25,
D. C, ATTN: ORDFM, using DA AGO Form 468, Unsatisfactory
Equipment Report. Such suggestions are encouraged in order that
other organizations may benefit.

Note. Do not report all failures that occur. Report only repeated or recurrent
failures or malfunctions which indicate unsatisfactory design or material. How-
ever, reports will always be made in the event that exceptionally costly equipment
is involved. See also SR 700-45-5 and the printed instructions on DA AGO
Form 468.

Section II. DESCRIPTION AND DATA

4. Description

a. The engine described in this manual is a Willys- Overland
4-cylinder, L-head gasoline unit (fig. 1, 2, and 3) with a counter-
balanced crankshaft. The camshaft is driven off the crankshaft
through gears (figs. 37 and 39). The oil pump (fig. 64) is located
externally on the left side of the engine and is driven by a gear cut
integrally on the camshaft. The "front" or timing-gear end of the
engine will be referred to as the front end. The "rear" or flywheel
end of the engine will be referred to as the rear end. The terms
"right" and "left," as used with reference to the engine, are as viewed
from the rear end and looking toward the front end. Cylinders are
numbered 1 through 4 starting at the front end. The distributor is
driven directly from the oil pump drive gear. Keference is made to
chapter 4, this manual, for complete information and to operator's
manual, TM 9-804, for tabular data.

h. The clutch (fig. 81) is a single plate 8i^-inch dry disk type. The
pressure plate (fig. 82) is well protected against corrosion for under-
water operation and three springs give a total plate pressure of from
990 to 1080 psi to provide 147 Ib-ft torque. The driving plate is faced
on both sides with center vibration neutralizer springs. Refer to
chapter 5 for complete information and tabular data.

€. The engine ventilation system for underwater operation (fig. 4)
consists of the standard crankcase ventilating system with the addi-
tional necessary external watertight tubes required to assure under-
water operation or prevent damage due to condensation. Detailed
information is contained in chapter 6 of this manual and all tabular
data in TM 9-804.

5. Data

Make and type ^ Willys-Overland 4-cylinder, L-head, in-
ternal combustion gasoline driven

Model MC

Over-all dimensions (including flywheel assembly)

Length 26.53 in

Width 21.16 in

Height 27.34 in

Dry weight complete with flywheel 365 lbs

Maximum brake horsepower 60 at 4,000 rpm

Maximum torque 105 Ib-ft at 2,000 rpm

Number of cylinders ^ 4

Figure 1. Left side view of power plant.

fA m 357991

Figure 2. Front view of engine.

mmmmmm

Figure 3. Right side view of power plant.

A - WINDSHIELD WIPER TO AIR ClfeANEH VENT IINE

» -aiEl TANK TO A(R CLEANBi VENT IM^

C -DASH EL0OW TO DASH TEE LINE

D » DASH aSOW

E ~ iUAKE MASTER CYLINOER TO DASH aBOW VENT INC

F - CARBURETOR TO AIR NTAKE PIPE

G - CRANKGASE VB^ VALVES

H- VACUUM LINE TIE

Figure 4- yentilation of units for deep water fording.

RA fp 3579*6

CHAPTER 2

PARTS, SPECIAL TOOLS, AND EQUIPMENT FOR FIELD
AND DEPOT MAINTENANCE

6. General

Tools and equipment and maintenance parts over and above those
available to the using organization are supplied to ordnance field
maintenance units and depots for maintaining, repairing, and/or re-
building the materiel.

7. Parts

a. Maintenance parts are listed in Department of the Army Supply
Catalog ORD 8 SNL G-740 which is the authority for requisitioning
replacements. Parts not listed in the ORD 8 catalog, but required by
depot shops in rebuilding operations, may be requisitioned from the
listing in the corresponding ORD 9 catalog and will be supplied if
available.

5. Standard and commonly used tools and equipment having gen-
eral application to this materiel are authorized for issue by T/A and
T/O&E, They are not specifically identified in this manual.

8. Special Tools and Equipment

The special tools and equipment tabulated in table I are listed in
Department of the Army Supply Catalog ORD 6 SNL G-27, Section I.
The tabulation contains only those special tools and equipment neces-
sary to perform the operations described in this manual, is included
for information only, and is not to be used as a basis for requisitions.

Note, Special tool sets in OKD 6, SNL G-27, Sec. I, in addition to special tools,
also contain standard and commonly used tools and equipment specifically appli-
cable to this material.

nmm^TOBMu

! I^^SS^^^m ff^^l^:^^

Figure 5. Special tools.

Table I. Special Tools and Equipment for Field and Depot Maintenance

Identifying Number

Keferences

Fig.

Par.

GAGE, valve cap clearance

41-G-500-90

41-P~2956-4

41-P-295&-15

7083446

41-R-2329-700

41-R-2379-25

7083262
7083263
7083261

5,62

5, 39, 40
5,48
5,49
5, 50, 51
46

44
44
46
43

Measure clearance between end of exhaust

PULLER, crankshaft and camshaft geai^

valve stem and rotator cap.
Removing crankshaft and camshaft gears.

PULLER, water pump, drive gear

Removing water pump drive gear.

PULLER, water pump impeller _

REFACER, water pump bushing

Refacing water pump.

REMOVER AND REPLACER, valve guide, in
set

Composed of:

ADAPTER

Removing and replacing valve guides.

ADAPTER .

DRIVER

CHAPTER 3
TROUBLE SHOOTING

Section I. GENERAL

9. Purpose

Note. Information in this chapter is for use of ordnance maintenance per-
sonnel in conjunction with and as a supplement to the trouble shooting section
in the pertinent operator's manual. It provides the continuation of instructions
where a remedy in the operator's manual refers to ordnance maintenance per-
sonnel for corrective action.

Operation of a deadline vehicle without a preliminary examination
can cause further damage to a disabled component and possible injury
to personnel. By careful inspection and trouble shooting, such dam-
age and injury can be avoided and, in addition, the causes of faulty
operation often can be determined without extensive disassembly.

10. General Instructions and Procedures

This chapter contains inspection and trouble-shooting procedures
to be performed while a disabled component still is mounted in a
vehicle and after it has been removed.

a. The inspections made while the component is mounted in the
vehicle are visual for the most part and are to be performed before
attempting to operate the vehicle. The object of these inspections is
to avoid possible damage or injury and also to determine the condition
of and, when possible, what is wrong with the defective component.

h. The trouble shooting performed while the component is mounted
in the vehicle is that which is beyond the normal scope of organiza-
tional maintenance. Check the trouble shooting section of TM 9-804
or any other pertinent operator's manual, to be sure the trouble is not
a defect normally corrected by the using organization, then proceed
as outlined in this chapter.

(?. Inspection after the component is removed from the vehicle is
performed to verify the diagnosis made when the component was in
the vehicle, to uncover further defects, or to determine faults if the
component alone is received by the ordnance installation. This in-
spection is particularly important in the last case because it often

is the only means of determining the trouble without completely
disassembling the component.

d. Trouble shooting a disabled component after it has been removed
from the vehicle consists of subjecting it to tests on a dynomometer.
This chapter discusses those symptoms which can be diagnosed by
using the testing equipment and interprets the results in terms of
probable causes.

Section IL ENGINE

11. General

Most engine troubles are accessory troubles. The trouble-shooting
portion of TM 9-804, or the specific manuals (par. \d^ 6, /, and g)
covering the particular accessories used with this engine normally
will cover the trouble shooting of all engine accessories. This section
covers only those troubles which can develop within the engine itself.

12. Procedure

a. Seizure of Parts. When an engine cannot be turned over by
hand or with a starter, seizure of parts is the cause. Remove the
starter and with a small bar, attempt to turn the flywheel. If the
flywheel can be turned the probable seizure is in the starter. If the
flywheel will not turn clockwise, seizure can usually be isolated to a
hydraulic lock. If flywheel will not turn in either direction, proceed
as outlined in the following paragraphs.

Caution: Exercise great care in deciding what inspection and re-
pairs must be performed. Parts in the nonseized section may be
strained or bent and require replacement, or presence of chips may
require a complete teardown and cleaning of the lubrication system.

h. Gear Failures. Gear and drive shaft failures generally can be
isolated by a systematic check of the affected gear train. Methods of
locating these failed gears is covered under the individual systems.
Gear failure repairs frequently can be confined to replacement of the
damaged parts.

Caution: Exercise great care in deciding what repairs must be
made. Disassembly and cleaning of part or all of the engine may be
necessary due to contamination of the engine lubricating system or
moving parts with chips.

c. Noise. Unusual engine noises can be caused by worn, broken, or
improperly adjusted parts and by lack of lubrication. Ability to iso-
late trouble causing a noise is a matter of experience and even then is
somewhat inaccurate. When noise occurs, shut down engine immedi-
ately for investigation. Some of the more common noises and their
causes are —

(1) Grinding noise. Turn the engine by hand. If it is some-
what tight and the grinding persists, a bushing or bearing
is probably failing. Refer to ^ above.

(2) Sharp tapping noise. A defective valve or incorrect valve
clearance will produce this sound. Start the engine and lis-
ten through a suitable length of pipe or a screw driver pressed
against the cylinder block. The tapping from the defective
unit will be much sharper and louder than from the others.

d. Air Intake Manifold and Valves.

(1) Preliminary instructions. Most induction system difficulties
are covered in the pertinent operator's manual. Difficulties
that are not covered therein and the methods of locating them
are listed under (2) below.

(2) Procedure. Examine the camshaft for damage. Follow
whichever of the following that applies :

{a) Camshaft damaged. If the camshaft is damaged, do
whichever of the following that applies :

1. Camshaft hearing or journal damaged. Eepair or replace

damaged parts.

2. Camshaft broken. Replace with new camshaft.

{h) Valve stuck. Remove valve cover. Turn the engine and
observe if all valve stems move up and down properly. If
any valves are stuck open, it will be readily noticeable. A
stuck valve will sometimes damage the camshaft. Repair
the valve difficulty and inspect the camshaft for conform-
ance to serviceability standards (par. 156).

e. Starting System.

(1) Preliminary instructions. Most defects are covered in the
pertinent operator's manual. A failure or seizure in the gear
train are other difficulties that may occur.

(2) Procedures. Turn the engine by hand. If it cannot be
turned, refer to a above. If it turns, attempt to crank engine
with the starter. If the engine does not turn over, remove
starter for repairs as outlined in pertinent technical manual
(par. 1).

/. Engine Low in Power. Stop engine and proceed as in <?(1)
above. If that is not the cause, trouble shoot as outlined in the perti-
nent operator's manual.

g. Engine Misfires and Runs Rough. Trouble shoot as outlined
in pertinent operator's manual and in d above.

h. Engine Fails to Start. Refer to pertinent operator's manual
and to d and e above.
i. Engine Lubrication System DEFEcrriVE.

(1) Preliminary instructions. Make the checks outlined in the
pertinent operator's manual. If the trouble is not isolated,
proceed as in (2) below.

953383—51 2 1 3

(2) Procedures,

{a) Low oil pressure. Obstructed oil passages or worn or
burned out bushings and bearings could cause this con-
dition. If the obstructing material in the oil passages is
something that might be throughout the rest of the engine,
rebuild the entire engine; otherwise, remove the obstruc-
tion. If worn parts are the cause, rebuild engine.
(b) Excessive oil consumption. Excessive oil consumption
caused by worn or scored engine parts should be diagnosed
carefully to determine whether a complete engine rebuild
or only a cylinder, piston and piston ring overhaul is
required.
j. Generating System. If tests in the pertinent operator's manual
do not isolate the trouble, remove and replace with new assembly.
Consult the pertinent technical manual for detailed instructions
(par. 1).

CHAPTER 4
ENGINE

Section I. DESCRIPTION AND DATA

13. General

The Willys-Overland Model MC engine is a conventional design
four-cylinder L-head-type unit (figs, 1, 2, and 3). The crankshaft
(fig. 43) is mounted on three replaceable shell-type bearings and is
counterbalanced to reduce vibration. Extra long connecting rods with
replaceable shell-type bearings and three- ring aluminum pistons are
used. The camshaft rotates on four bearings, the rear three being
reamed openings in the crankcase and the front a replaceable, babbitt-
lined steel bushing. The camshaft is driven by helical cut timing
gears (fig. 37).

14. Engine Lubrication System

Engine lubrication is accomplished by a force-feed continuous cir-
culating system. An oil pump (figs. 64 and A, fig. 28) mounted ex-
ternally on the left side of the engine and driven by a gear cut integ-
rally with the camshaft provides the necessary oil pressure. Drilled
passages in the crankcase provide oil flow to the cranksaft and cam-
shaft bearings and passages in the crankshaft provide oil flow to the
connecting-rod bearings and timing gears. The pistons and valve
tappets are lubricated by oil spray from the connecting rods.

15. Electrical System

The engine electrical system is of the 24-volt type. All electrical
units are sealed to allow operation underwater and where necessary
shielded to provide satisfactory radio interference suppression.

16. Crankcase Ventilation System

The engine crankcase is sealed to allow operation underwater. It
is ventilated through a line (fig. 4) connected to a vacuum-controlled
valve mounted in the intake manifold. A sealed-intake hose provides
air for underwater operation. Crankcase ventilation may be blocked

off by closing control valves (fig. 85) to provide build up of pressure
within the crankcase to prevent water from entering the engine when
the vehicle is submerged.

17. Power Plant

The vehicle and the engine, transmission, and transfer, are designed
to permit removal of the complete power plant with minimum labor
(fig. 23). The power plant rear mounting in the chassis is at the
transmission, which makes it impossible to place the engine, without
transmission and transfer attached, on a stand for test. The entire
power plant must be removed when it is necessary to remove the engine
for rebuilding.

18. Data

Cylinder bore 3.125 in

Piston stroke 4.375 in

Piston displacement 134.2 cu in

Compression ratio 6.48 to 1

Valve-timing setting Intake closes 50° after top center

with 0.020-in clearance
Valve clearance Hot or cold engine) :

Intake 0.016 in

Exhaust 0.016 in

Valve events :

Intake opens 9° before top center

(0.039-in piston travel)

Intake closes 50° after top center

(3.722-in piston travel)

Exhaust opens 47* before top center

(3.799-in piston travel)

Exhaust closes 12° after top center

(0.050-in piston travel)

Ignition timing Set 5* before top center

(automatic advance)

Spark-plug gap 0.030 in

Firing order 1-3^^2

SAE horsepower 15.63

Accessories (number of each) :

Generator 1

Starter 1

Spark plugs 4

Carburetor 1

Fuel pump 1

Generator output 25 amp 28.5 v

Section II. POWER PLANT REMOVAL FROM VEHICLE

19. General

a. Both the vehicle and power plant are designed to permit removal
of the power plant, which includes the engine, radiator, clutch and

housing, transmission, and transfer as a unit, with a minimum of time
and labor. Should other than minor engine adjustments be required,
remove the entire power plant assembly (par. 20) .

h. All disconnect points are painted yellow as a guide for removing
the assembly.

20. Removal of Power Plant

a. Disconnect Battery Cable. Unhook the two hood clamps,
raise the hood and lay it against the windshield. Disconnect the bat-
tery ground cable (fig. 6) .

L *

'--■■■-•■"--'■-■'■-"-''•■■••'^^

mtim

G)%OUND CABLE^^^^^^^K^H

Figure 6. Battery disconnect point.

d. Disconnect Eadiator-Beace Eod (fig. 7) . Loosen retaining nut
on radiator ; remove brace rod from slotted bracket, swing rod out of
position from pivot end, and lay brace rod on cowl.

c. Eemove Hinged Radiator Guard. Disconnect the three head
light cable connectors at the left-front head light (fig. 8) . Loosen the
top bolt, at each side of the radiator guard panel and loosen the two
lower bolts, on each side (fig. 9). Lay the radiator guard assembly
forward on the bumper and remove guard from hinge sockets.

d. Disconnect Eadiator From Frame Cross Member. Working
from underneath, remove the two nuts and lock washers which attach
the radiator to the frame cross member (fig. 10) .

e. Disconnect Oil-Pressure- Gage and Water-Temperature-Gage
Sending Units. Disconnect the oil-pressure-gage sending unit cable
(figs. 7 and 32) located on the left side of the engine. Disconnect the
water temperature gage sending unit cable on the right side of the
cylinder head (fig. 11) .

A ^ RADIATOR BRACE ROD OISCONHECT POINT
B - CHOK£ CABLE
C -~ THROTTLE CABLE

D ™ VENTllATiNO VALVE CONTROL CABLE
E - Oil PRESSURE GAGE SENDING UNIT DISCONNECT POINT
f_„ WINDSHIELD VESPER HOSE DISCONNECT POINT

O ^ VENTILATING VALVE CONTROL CABlg RA PD 357972

DISCONNECT POINT

Figure 7, Engine compartment disconnect points.

Figure 8. Bead light disconnect points.

A ™ RADIATOR GUARD TOP BOLT
ft _ RADIATOR GUARD tOWSt BOLT
C ™ RADIATOR GUARD HINCe

.::■*: ■..:...■ ^m~^S7W4

Figure 9. Radiator guard disconnect points.

Figure 10. Radiator disconnect points.

PD 357976

Figure 11. Water-temperature-gage sending unit disconnect point.

f. Disconnect Exhaust Pipe (fig. 12) . Eemove the two nuts that
secure the exhaust pipe to the intake manifold. Pry the exhaust pipe
from the intake manifold.

^^^^^^BvAOHS^SMPt^l^

m^^m FUEL FSIMER LfNE DiSCONhKr^ IC

Iffl

m\ mm^^^^^^ .,::V.. ■— -- ■■■ ■■

o!^^57977^HHb9^^BI

Figure 12. Left side of engine disconnect points.

g, Discoifl^NECT Fuel and Vacuum Lines. Disconnect fuel tank
line hose connector from fuel pump (fig. 30) and disconnect primer
line at intake manifold (fig. 12). Disconnect windshield wiper hose
from vacuum line at vacuum line tee (fig. 15) .

A. Disconnect Choke and Throttle Control Cables (fig. 7) . Re-
move the nut and bolt from the choke and throttle hold down bracket.
Loosen the set screw on the carburetor choke lever and remove the
choke control cable. Disconnect accelerator from ball connection at
floorboard (fig. 17).

L Disconnect Ventilating-Yalve Control Cable. Remove the
bolt and nut on the ventilating valve control bracket. Loosen the set
screw on the ventilating valve mounted on the manifold and remove
the ventilating-valve control cable (fig. 7). Loosen the set screw on
the ventilating valve directly to the rear of the oil filler tube and remove
the ventilator valve control cable (fig. 13) .

;/'. Remove Air Cleaner (fig. 13). Disconnect windshield-wiper
and fuel-tahk-to-air-cleaner vent lines at air cleaner. Disconnect air-
cleaner-to-dash-tee line at air cleaner. Loosen the hose clamps that
secure the air-cleaner hoses at the air cleaner and remove the hoses.

A -™ WNDSHiStD WIPER HOSE DiSCONNECT K)iNT
B -AIR CIEANER INLST HOSE
C~Am CLEANER BRACKET DISCONNECT POINT
D -Alft CLEANER

E-rua TANK TO AIR CLEANER VENT LINE

F ~ AIR CLEANER OUTLET HOSE

0™ SPARK PLUG CABLE

H - VENTILATING CONTROL VALVE CABLE HOLD DOWN BRACKST .

J - HOSE CLAMP ■ :wv„j^-..r^ r-^^---:-:^^^

K - VENTILATING CONTROL VALVE CABLE '■^^..W^^:m

Figure 13. Disconnect points.

Kemove the four wing screws that secure the air cleaner to the mount-
ing bracket located at the right side of the cowl and remove air cleaner.

h. Disconnect Electrical Cables. Disconnect the starter, auxil-
iary power receptacle, and generator regulator cables at the starter
terminal (fig. 14). Disconnect the field, armature, and ground cable
by disconnecting the plug from the connector at the generator (fig.
16) . Disconnect primary cable at distributor (figs. 14 and 16) .

I. Eemove Floor Plate and Shipt Levers. Place transmission
gearshift lever in neutral (TM 9-804) . Remove the 24-cap screws and
internal toothed lock washers from the floor pan (fig. 17) . Remove
transfer gear shift lever knobs. Remove the floor pan. Loosen clamps
securing rubber boot to the transmission gear shift housing (fig. 17).
Slide boot up and unscrew gearshift lever (fig. 18) . Remove gearshift
lever. Unscrew the fulcrum pin (D, fig. 20) and remove the transfer
gearshift levers. Remove brake-pedal-shaft-clamp bolt and remove
brake-pedal shaft (fig. 18).

Figure H. Disconnect points,

m. Disconnect Front and Rear Propeller Shafis (figs. 19, 20,
and 21). Remove the four bolts, nuts, and lock washers securing the
propeller shaft flanges to the transfer. Tie the end of the front shaft
to the frame with a piece of wire.

n. Disconnect Speedometer Cable (fig. 22). Disconnect the
speedometer cable at the transfer.

o. Remove Hand Brake, Clutch, and Engine Stay Cables (fig.
21). Remove the clevis pin that secures the hand-brake cable to the
hand-brake control lever at rear of transfer case. Remove the hand-
brake-cable clamp at the engine support plate. Disconnect the clutch

A ™ THROTTLE CABLE DISCONNECT POINT

B ~ CHOKE CABLE DISCONNECT POINT

C - VACUUM DISCONNECT l»OiHT

& - LEFT WINDSHiaO WIPER NOSE DISCONNECT POINT

E ^VgNtriATiNG VALVE CONTROL CABLE DISCONNECT POINT

RA PO 357996

Figure 15. Disconnect points.

cable at the clutch shaft. Loosen nut on each side of transfer case to
allow engine-stay-cable ball socket to slide freely and remove engine
stay cable.

p. Attach Lifting Hook (fig. 23) . Install a lifting hook in the
rear lifting eye on the cylinder head. Place a slight tension on the
lifting chain or cable.

q. Disconnect Engine Front Supports (fig. 24). Kemove the
two nuts and bolts from each engine front support, allowing the
mounting brackets to remain attached to the engine. When this opera-
tion is performed the engine ground strap at the engine right-front
support will be disconnected.

r. Disconnect Transmission From Frame (figs. 19 and 20). Re-
move nut and washer securing right side of transmission and transfer
case to frame cross member. Remove nuts on right and left side secur-
ing transmission and transfer case to frame cross member to permit
power plant to slide to right for easy removal.

s. Disconnect Clutch Linkage. Move the rear of the power
plant to the right and disconnect the clutch linkage at the ball stud
(fig. 21).

Figure 16. Disconnect points.

mmm^M-

A - ACCEIERATOR PEDAL OlSCONNea fOim

S - TRANSMISSfON GEAR SHlfT LEVER 800T ClAMF

C ~~ BOOT

D - FLOOR PAN SCREW

E _ TRANSFER OBM SHIFT lEVEf^ SOOT

F - RETAINiNG RING

mm 357980

Figure It. Disconnect points.

A-TRANSMISStON GEAR SHI?T tEVER DISCONNECT POiNT

B^CtUTCH UNKAGE DISCONNECT POINT

C-SRAKE PEDAL SHAfT

&-81tA!CE PEDAl SHAFT DRAFT PAD SPRING

fi^BRAKE PtDAl SHAFT WASHER

F-BRAKE PEDAl SHAFT PAD

0-ERAKE PEDAL SHAFT DISCONHfiCT POINT

RAPD 357981

Figure 18. Disconnect points.

MH^HJ^wiW^^^^^^^^^^BpRO^t^t. SHAFT DISCONNECT {>0INTM

Bp ; J TltANSMiS$tON &iSCONNfcC!_gOjHj|^

Figure 19. Disconnect points.

A^mMT vm?m.^ sha?t mscotmEa point

B-TftANSFSIi-TR^^SMISSlON DISCONN^T K^NT
C-TRAH^SR VENT UHE

0~TSANSre» GEAR SHIFT lEV^ DISCONNECT POINT
E-BtAN^R-HeAHSMfSSlON DlSCONNEa POINT

Figure 20. Disconnect points.

fiA PD 3579^3

A - ENGINE STAY CABLg

B-HAND &RAKE CABLE

C ^ ENGINE STAY CABLE DISCONNECT POINT

D" CLUTCH LJNKAOE BAIL STUD DISCONNECT POINT

E ~ HAND 8KAKE CABLE DISCONNECT POINT

F ™ REAR PROPELLER SHAI^T DISCONNECT POINT

;lA:fi>-::-:|iliPj

Figure 21. Disconnect points.

Figure 22, Speedometer caUe disconnect points.

t. Remove Power Plant From Vehicue.

^ote. Make sure all disconnects have been accomplishad.

While rolling the vehicle to the rear, carefully lift power plant out
of vehicle (fig. 23) . Block up power plant.

il::::;;ii:::|l||i:l|iliiliiiiii:^^

Figure 2S. Lifting power plant from vehicle.

Figure 24. Disconnect points.

953383—51 3

Section III. PREPARATION OF ENGINE FOR REBUILD

21. Drain Coolant and Oil

Drain the coolant from the radiator and the engine by opening the
radiator drain cock (fig. 30) and the drain cock located on the right side
of the engine. Kemove the oil pan drain plug and drain the engine oil.

22. Removal of Radiator

Loosen the two radiator outlet hose clamps and slide the hose back on
the metal tubing and remove the hose. Loosen the radiator inlet hose
clamps at the water pump and at the radiator and remove the hose.
Lift radiator from support rods {G.g. 25) .

23. Removal of Starter

(fig. 26)

Remove the cap screw and lock washer that secures the starter
bracket to the cylinder block. Remove the two cap screws and lock
washer that secure the starter to the clutch housing, and remove the
starter.

A - ROD, SUPPORT, RADiATOI^ TO ENGINE/RIGHT - 7372804

B - RAOJATOR, W/ SHROUD, ASSEMBLY - 7372B01

C » NUT, fiADlATOR MOUNTING ~ 1 20370

D - COCK, DRAIN, RADIATOR ™ 103647

E ^ PUilEY, DRIVE, FAN AND GENHRATOR ^ 73725;§g

F ™- COVEr?, TIMING G€AR ^ 7372576

G ^ PUMP, FUEL AND VACUUM - 7375380

H ~ PAN, Oil -7371 278

J ™ PLUG, DRAIN, 7/8 IN » 340661

K - PfPE, EXHAUST - 7375077 .

l ™ CABIE, HAND BRAKE - 7375066

M ~ CABie, STAY, ENGINE - 7372548

KA PD 357945

Figure 25, Underside view of power plant in vehicle.

Figure 26. Starter mounting screws.

24. Removal of Transmission and Transfer

(figs. 28 and 29)

Remove the two nuts, bolts, and lock washers on top of clutch hous-
ing. Eemove the remaining four bolts and nuts securing the clutch
housing to the engine rear plate and remove clutch housing, transmis-
sion, and transfer as a complete unit.

AfR CLEAHEt .

Am CtEAHS. TO FUa TANK VENT UNE ^g

C - A!R CLEAHER HOSE ClAMP
-^ASS CLEANER OUUO HOSE

K -^ VENTiLATOi? VAiVE CONTtOl CASIE BHACKST:!!
f -VENTIIATOR VAiVE CONTROL CA&Li

Am INTAKE PIPE

WATER OUTIET eiBOW {THERMOSTAT HOUSING);

RADIATOR BRACE ROD

CARSURETOR

•RAOIATOt TO WATER OUTLET ElBOW HOSE f

■WATER PUMP
N '- RADIATOR SHROUD
P - Oa FILLER PIPE CAP

n - BATTERY BOX

S - GENERATOR

T - VOiTAGE REGULATOR

U - DISTRIBUTOR

RA PD Z57997

Figure 21. Front view of engine compartment.

HAW 33^«4« X W

Figure 28. Three-quarter left rear vietv of power plant.

A— PUMP, OIL ASST~7375072

B— UNIT, SENDING, ENGINE OIL PRES-
SURE— 7728856

C~MANIFOLD, INTAKE, W/STUDS—
7372562

T>~MANIFOLD, EXHAUST— 7375054

E— LINE, VENTILATION, DISTRIBUTOR,
13-INCHES LONG

F— S HAFT, CROSS, ACCELERATOR,
W/LEVER, AND B R A C K E T—
7375069

G— SPRING, RETURN ACCELERATOR—
7375068

H— ROD, CONTROL, THROTTLE—
7375111

J— PLUG, EXPANSION— 541402

K— COVER, VALVE SPRING COMPART-
MENT— 7371237

L— HOUSING, CLUTCH— WO-801629

M— LEVER, TRANSMISSION, GEAR-
SHIFT— 7374974
N— COVER, INSPECTION, CLUTCH—

7371341
P— HOUSING, GEARSHIFT LEVER—

WO-801730
Q— DRUM, HAND BRAKE— 7371010
R— LEVER, OPERATING, HAND BRAKE—

7697434
S— STUD, BALL, CONTROL LEVER

TUBE— A246557
T— BRACKET, MOUNTING, R E A R—

7372544
U~CABLE, CONTROL TUBE LEVER—

7372821
V— NUT, HEX— 120369
W — SUPPORT, ENGINE OIL PRESSURE

GAGE SENDING UNIT— 7375148
X— DRAIN PLUG— 340661

Figure BS.—Continued

RA PD 357946
Figure 29, Three-quarter right rear vieto of power plant.

A— COVEK, TRANSFER CASE, REAR— R— LINE, VENTILATING, DISTRIBUTOR

WO-A1508 TO AIR INTAKE PIPE

B— SCREW, CAP, yi6-14NC x 1^—122267 S— UNIT, SENDING, ENGINE WATER
C— HOUSING, TRANSMISSION GEAR- TEMPERATURE GAGE— 7728851

SHIFT LEVER— WO-801730 T— PLUG, EXPANSION— 541402

D— LEVER, TRANSMISSION GEAR- U— DISTRIBUTOR, W/COIL~7375375

SHIFT— 7374974 V— STARTER— 7762616

E— L EVER, TRANSFER GEARSHIFT W— PAN, OIL— 7371278

(FRONT LEVER DRIVE)— 7374966 X— SCREW, CAP, %-24NF x 1%

F— COVER, INSPECTION, CLUTCH— Y— NUT, %6-14NC— 120369

7371341 Z— HOUSING, CLUTCH— WO-801629

G— UNIT, SENDING, ENGINE OIL PRES- AA— SCREW, CAP, %-24NF x 1%

SURE GAGE— 7728856 AB— SHAFT, SHIFTER, TRANSFER
H— SHAFT, CROSS, ACCELERATOR CLUTCH GEAR FORK— WO-A962

W/LEVER, AND BRACKET— AC— YOKE, FRONT PROPELLER SHAFT

7375069 TO TRANSFER, W/SHIELD—

J— LINE, VENTILATION, DISTRIBUTOR 7371208

TO VACUUM LINE TEE AD — CASE, TRANSMISSION— 7372877

K—PLUG, SPARK— 7524258 AE—CASE, TRANSFER- 7375051

L— CARBURETOR— 7372509 AF— DRUM, HAND BRAKE — 7371010

M— LINE, VENTILATING, CARBURETOR AG— FLANGE, COMPANION, REAR PRO-

TO AIR INTAKE PIPE PELLER SHAFT— 7371035

N— HOSE, CARBURETOR TO AIR IN- AH— SCREW, LOCKWASHER, %-16NC x

TAKE PIPE— 7375120 %— 443608

P— EYE, LIFTING— 7375026 AJ— LEVER, TRANSFER GEARSHIFT
Q— CABLE, SPARK PLUG— 7528173 AND (HIGH AND LOW RANGE)—

7528174 7697470

Figure 29. — Continued

25. Removal of Carburetor

(fig. 27)

Loosen hose clamp securing hose to carburetor, slide clamp back
on hose and remove hose (fig. 27) . Remove carburetor air vent line
from carburetor (fig. 32) and move line out of way. Remove the
fuel line connecting the carburetor and fuel pump. Remove the ac-
celerator return spring from the carburetor and accelerator lever (fig.
31) . Disconnect throttle control rod at the adjusting block. Remove
the two carburetor hold-down nuts, lock washers and accelerator
spring clip, and remove carburetor.

26. Removal of Fuel and Vacuum Pump

(fig. 30)

Disconnect fuel lines at fuel pump. Disconnect the two vacuum
lines at base of pump. Remove the two screws and lock washers that
hold the fuel pump to the cylinder block, and remove the fuel pump.

27. Removal of Generator

(fig. 33)

Remove generator- adjusting-brace cap screw. Loosen the two gen-
erator pivot bolts. Raise the generator to release the tension on the
two fan belts, and remove the two belts. Remove the two pivot bolts
that hold the generator to the support bracket, and remove the gen-
erator. Remove the two cap screws that hold the support bracket to
the cylinder block, and remove the bracket.

28. Removal of Oil Filter

(fig. 27)

Disconnect oil filter inlet and outlet lines at the filter. Remove the
cap screw that secures the oil-filler-pipe clip to the cylinder block.
Remove two oil filter bracket screws and remove oil filter. Remove
the three cylinder head nuts that hold the oil filter mounting bracket
to the cylinder head and remove the bracket.

29. Removal of Distributor

(fig. 33)

Disconnect the four spark plug cables at each plug. Slide the
cables through the spark plug hold- down bracket. Disconnect the two
vent lines at the distributor. Remove distributor mounting cap screw
and remove distributor.

A - COCK, DRAIN, RADIATOR - 103647

B - Um, PUMP TO FUEL TANK ^ 7375038

C- PUMP, FUEL AND VACUUM - 7375380

D-UNE, FUEL PUMP TO CARBURETOR - WO-S0 1380

£ -LINE, VACUUM PUMP TO VACUUM UNE TEE - WO-800870

F - SCREW, 5/16-18NC x 2 -7375385

=M PD 35^00$

Figure 30. Removal of fuel pump.

A-cAmmmoti

& - THRO.mE AND CHOKE CONTROL CA816 CONDUIT CtAMP

C - THROniE CONTROL ^OD

- THROHLE CONTROL ROD ADJUSTING BLOCK

t - THROTTLE CONTROL

F ~ CHOKE CONTROL

™ ACCELERATOR CROSS SHAFT
H ™ ACCEiERATOt FEOAl

J ^ ACCELERATOR PEDAL HNGE
K ™ ACCELERATOR FOOT REST

1 ~ ACCELERATOR PEDAL. TO CROSS SHAFT LEVER CONNECTOR

M - ACCELERATOR PEDAl TO CROSS SHAFT LEV£i? CONNECTOR BOOT
N ™ ACCELERATOR RETURN SmiHG CLIP {THROTTlE CONTROL ROD ADJUSTING SLOCK?
P -»• ACCELERATOR fiETURH SPRING

Q - ACCELERATOR UBUm SPgINO CLJP |CARSUf?IETOI? MDUHTfHG STUD)
R - MANIFOLD

S ™ THROHLE VALVE LBVER STOP ADJUSTING SCREV/
T~THROTUE CABLE 'STOP
U ^ THROTTLE LEVER
V - CHOKg CONTROL CABli CLAMP SWIVEL SC8EW

RA Pp 357W

Figure 31. Accelerator and choke linkage.

30. Removal of Fan

(fig. 32)

Eemove the four cap screws and lock washers that hold the fan to
the fan and water pump pulley and remove the fan.

A " FAN AND OENERATOR DRJVE PUUEV GUARD T

g ^ CRANKSHAFT NUT U

c - GEAR covm V

D - FAN W

g ^ fAN AI^D WATER PUMP PULLEY X

f ™ FAN 8EITS - Y

O -~WAT£R PUMP Z

H - SY.PASS TUSE AA

4 ^ Oft urn AB

K - OIL FILTEJ? AC

I - Ofl FIILSR ?(Pe AD

M - Oil FillEii PIPE CAP AMD GAO£ AE

N - VENTILATiNG VAi.V£ AF
P „ WATER OUTIET ElBOW {THERMOSTAT HOUSING) AG

™ UFTiNG EYE AH

n ~- CARBUfiETOR TO AIR INTAKE flPE HOSE AJ

S- CARBURETOR CHOKE VAIVE BODY WC

CARBURETOR VENT UNE

CHOKE CABIE HOLD DOWN CUP

CARBURETOR

CARBURETOR FUEl LiNE

THROTTLE iEVER

ACCELERATOR RETURN SPRING

VENTltATiNG VAtVE

PRIMER PUMP UNE

VACUUM PUMP UNE

CRAHKCASE VBMT UNE

VALVE SPRiNG COMPARTMENT COVSR

COVER SCREW

Oil PRESSURE GAGE SENDING UNIT ;

0!L PUMP

ENGINE REAR PiATE

FUEL AND VACUUM PUMP

FUEl iNlET LINE ELBOW

Figure 32. Left-front view of engine.

A - PRESSUSg PtATE
B ~~ FlYWHESl
C - ENGINE RiAJ? PIATE
D - OJL PRESSURE GAGE SENDiNG UNIT
E *- ACCELERATOR CROSS SHAFT
F_ EXPANSION PLUG
O- WATER TEMPERATURE GAGE SENDING UNIT

n ™ msTRiauTOR vmT im^

J -- DISTRIBUTOR COVER
K~ SPARK PlUG CABLE

t ^ DISTRI&UTOR VENT UNE
M-AIRJNTAKE PIPE

I^UlVlNmAtJNQ CO^TROl VALVE

'tlt^;U^^)^:mmJEf ElBOV/ {THERMOSTAT MOUSINGI

8 - Oil FllLER PfPE CAP AND GAGE

S - Oil FILTER BRACKET

T ™ Oil FILTER

U - on FILLER PIPE CLIP

V -FAN

W ^ Otl FILLER Pm
X^ WATER PUMP

Y _ FAN &aTS

t - DISTRIBUTC^ W/COIl
AA ~ GB^ERATOR
A6 ™ STARTER SWITCH
AC ™ STARTER

Ab ^ ENGINE GROUND STRAP
AE-OIL PAN'

Figure 33. Right-rear view of engine.

Section IV. DISASSEMBLY OF STRIPPED ENGINE INTO
SUBASSEMBLIES

31. Removal of Water Pump

(fig. 27)

Loosen the two clamps securing the by-pass tube (fig. 32) between
the water pump and cylinder head, and remove the tube. Kemove
the four cap screws and lock washers that hold the water pump to
the cylinder block (fig. 27) and remove the water pump.

32. Removal of Intake and Exhaust Manifold

Eemove the crankcase vent line that connects the intake manifold
and valve compartment cover (fig. 32). Kemove distributor to
vacuum-line-tee vent line. Kemove the seven nuts, and lift the intake
and exhaust manifold off the engine.

33. Removal of Water-Outlet Elbow and Thermostat

(fig. 32)

Kemove the three nuts and lock washers that secure the water outlet
elbow to the cylinder head and remove the elbow. Remove the thermo-
stat retainer and thermostat.

34. Removal of Clutch Disk

(fig. 33)

Lfoosen the six pressure-plate-cover cap screws in sequence, a little
at a time, to prevent distortion of the pressure-plate cover. Remove
the six cap screws, pressure plate cover, pressure plate, and clutch disk.

35. Removal of Flywheel

(fig. 33)

Remove the two cap screws and four nuts and lock washers that
hold the flywheel to the crankshaft. Tap the flywheel off the crank-
shaft with a brass hammer. Lift the engine rear plate from the
engine.

36. Removal of Cylinder Head

(figs. 36 and 41)

Remove the lock washers and nuts that secure the cylinder head to
the cylinder block, and remove the cylinder head, lifting eyes, air
intake pipe and oil filler pipe.

37. Removal of Valves and Springs

Remove the two cap screws and crankcase vent body from the valve
compartment cover, and remove the cover. With a valve lifter 41-L-
1410 inserted between the valve tappet and valve-spring retainer,
compress the valve springs of the valves that are in closed position,
and remove the valve-spring-retainer locks (fig. 34). Turn the
crankshaft to lower the tappets and remove each retainer lock. Re-
move the valves and place them in a valve carrying board so that they
will be installed in the same positions, dompress the valve spring
with the valve lifter on each valve tappet that is in the closed position
and pull the spring off the valve guide. Turn the crankshaft until
the tappets are in the lowest position and remove each valve spring.

A -^ SPRING, VALVE ~- 7375035
8 ™ RgTAINER, VALVE SPf^ING - 7371236
C ~ UFTER, VALVE «- 4t.L"1410
D ™ LOCK, VALVE SPRING RETAINER ™ 7371230
E ™ TAPPET, VALVE - 7372585

F ^ SCI?EW, ADJUSTING, VALVE CLEARANCE - 7371 25S
G ™ CAMSHAFT - 7744320

Figure 3Jf. Removing valve spring retained locks.

8A PD 357951

'A- ^i;.

A—DISTRIBUTOR, W/COIL, ASSY

B— CYLINDER HEAD GASKET

C— EXHAUST VALVE GUIDE

D— INTAKE MANIFOLD

E— V A L V E SPRING COMPARTMENT

COVER
F— HEAT CONTROL VALVE
G— VENT BODY TO VALVE SPRING

COVER GASKET
H— EXHAUST MANIFOLD
J— V A L V E SPRING COMPARTMENT

VENT BODY
K— DISTRIBUTOR SHAFT FRICTION

SPRING
L— DISTRIBUTOR AND OIL PUMP DRIVE

GEAR
M— OIL PUMP TO CYLINDER BLOCK

GASKET

m^m;;^^4^:

N— OIL PUMP

P— OIL PUMP BODY COVER

Q— OIL PUMP PRESSURE RELIEF

VALVE
R— VALVE SPRING
S— VALVE SPRING SHIM
T — VALVE SPRING RETAINER
U— OIL PUMP SHAFT
V— OIL PAN
W — DRAIN PLUG
X— OIL STRAINER SUPPORT
Y— BEARING DOWEL PIN
Z— MAIN BEARING CAP SCREW
AA— OIL STRAINER
AB~OIL FILLER PIPE
AC— OIL FILLER PIPE AND GAGE
AD--SPARK PLUG CABLE

Figure So. End sectional mew of engine.

953383—51-

mft>:^^r^

A— FAN

B— WATER PUMP
C— BY-PASS TUBE
D— PISTON
B— PISTON PIN
F— WATER OUTLET ELBOW
G— VALVE
H— SPARK PLUG
J— CYLINDER HEAD
K— EXHAUST MANIFOLD
L— CYLINDER BLOCK
M— VALVE SPRING

N— VALVE CLEARANCE ADJUSTING
SCREW

P— ENGINE REAR PLATE

Q— CAMSHAFT

R— FLYWHEEL

S— VALVE TAPPET

T— CRANKSHAFT

U— OIL STRAINER SUPPORT

V— OIL STRAINER

W— CONNECTING ROD

X— CRANKSHAFT GEAR

Y — FAN BELT

Z— CRANKSHAFT NUT

AA— FAN AND GENERATOR PULLEY

AB— ENGINE FRONT PLATE

AC— CAMSHAFT GEAR

Figure 36. Side sectional view of engine.

C _ WASHER, PlAtN" 774 U06
^ <^AR. CftANK$HArr » 774 14 1 5
€ -. OtAK CAMSHAfT - 7741 4 J 9
f ™ HATE, THRUST ^ 7744320
G ~ SPACE!!;. THRUST PtATE ™ 774 J 407
H ~- KEY, 3/16 X. 3/4 - 124549
J ™ SEARING, BUSHING TVPE- 7744319
K » VAlVg - 7036579
L ^ SPRING, VALVE ^ 7371235
M - RCTArNER, VAIVS SPRING » 7^7 n3^
N^tOCK, VAIVE SPRING RETAlNa^ 7371238
P ^ SCREW, ADiUSBNG, VAlVg CIEARANCE -^ 7371 25S
Q _ TAPPET, VAtVE - 7372585
it -CAMSHAFT -77414 18

|~.

^ SmiHIID

Figure S7.

|?AP& 357917

Camshaft, crankshaft and camshaft gears, and valves— exploded

view.

38. Removal of Oil Pan and Oil Strainer

Turn the engine on its side. Remove the cap screws that secure the
oil pan and fan pulley guard to the cylinder block (figs. 32 and 38).
Remove oil pan and gasket. Remove the two cap screws from the oil
strainer support and remove the oil strainer and gasket (fig. 38),

39. Removal of Camshaft Gear and Camshaft

Remove the crankshaft nut and crankshaft pulley. Remove the
eight nuts, lock washers and bolts that secure the engine front plate
to the cylinder block and remove the timing-gear cover. Remove
Woodruff key, oil slinger, and thrust washer. Remove cap screw
and lock washer that secures the camshaft gear and remove cam-
shaft gear washer. Using puller 41-P-2956-4 remove camshaft and
crankshaft gears (figs. 39 and 40).

Note. When removing the camshaft gear, remove one camshaft thrust plate
cap screw to allow proper seating of puller without disturbing timing marks on
crankshaft and camshaft gears.

SUPPORT, OIL $tSA)NH-*7371244

. SCREW, tccKv/ASHe,.: : ■■:
sJh - isNC X 3/4 ^ \m6n

■liyrP0m^.-.:WO-63O398
■' ■.■^G^ICgT. Olf PAH-

PAN, Olt-737 1278

■^Si^fi; DRAIN, PI.UG-^737 1284

■: SCREW, ^/!6™ 13NC x 5/8 __«

■ . ^ 1 20220 ■■ '"jL

** «i

WASHER, iOCK
- 120214

PLUO, DRAIN ™ WO-63P97^
RAPD 357988

Figure 38. Oil pan — exploded view.

Remove timing gear oil fitting. Remove remaining cap screw and
remove camshaft thrust plate, Woodruff key, and thrust plate spacer.
Remove three l^-inch cap screws and lock washers securing oil pump
to cylinder block and remove oil pump. Lay the cylinder block on
its side. Pull all the valve tappets toward the top of cylinder block,
and remove the valve tappets. Remove three cap screws and exter-
nal toothed lock washers, and two nuts and lock washers securing
engine front plate to cylinder block and remove the plate.

40. Removal of Pistons and Connecting Rods

(% 42)

Remove the two jam nuts, two connecting rod bolt nuts, and connect-
ing rod bearing cap from each connecting rod. Remove all carbon
from the top of the cylinder walls. Tap the connecting rod and piston
out of the cylinder block with the handle end of a hammer. Install
the connecting rod caps on the rods in the same position as originally
installed to insure proper mating of parts upon assembly.

A - GEA!?, CRANKSHAFT- 774 1 41 5
8-RTTJNG, OIL- 7372557

C-Omn, CAMSHAFT -774 141 a
0-PyUER-'4NP.2W6-:4: .

Figure 39. Removing camshaft gear using puller Itl-P-2956-^.

A-~FtniNG, Oil™ 7372557

8~PUTE, THRUST™ 7744 3 20

C- SPACER, THRUST PLATE ™ 774 1 407

D~- CAMSHAFT -- 7741418

I ~~ GEAR, CRANKSHAFT -774U\5

F-~PUU£R-:4l-P-2956-4

Q-wkiHCH, opm-mo

RA PD 358001

Figure J^O. Removing crankshaft gear using puller — J^l-P~2956-Ii.

A- NUT --76978^

B - KEY, WOOOaUf F ^ 1 24549

C - PUttr, TWIN GROOVE, FAN AND GgNgRATOR DRIVE - 7372558

- COVER, TfMING GiAR - 737257«

E -- SEAL, on, CRANKSHAFT -^7375028

f - SUNGER, Oil, FfiONT™737M6!
G - GASKET, COVeR ™ 7371 \59
H ~ PLATE, ENGfNE, FRONT - 7372578

J - HEAD, CYLINDER - 7Z72S56

K -^ GASKET, CYUNDER HEAD -774141 2

1 ™ BIOCK. CYUNDER - WO - 800 1 00
M - PUTE, ENGINE. REAR - 737502?

N ~ SEAL, Oil, REAR BEARING - 73725A0
? - BEARING, MAIN, REAR » {USE SET 7371 493J
» SCREW, BEARING CAP - 7371 227
8 ^ BEARING, MAIN, Ce^TER - (USE SET 7371493)
S --BEARING, MAIN, FRONT ~ 73725*4 {U$E SET 7371493J
T - BEARING, CAMSHAFT, &USHiNG TYPE - 7744319
U - GASKET, ENGINE FRONT PLATE - 7741 427
V ~ CUSHION, MOUNTING, FRONT - 7372550

HAPti tUS^Om

Figure J^l. Cylinder Hock, main bearings, and head — encploded view.

;|fi;t;f||:=|l|::|;|;|||||||:::i||||i

SSiSl^S^i?;^ WK^:-:3y^8.:-:EN 'miomi:'::. : ■: '

siiii

Figure 42. Connecting rod — exploded view.

41. Removal of Crankshaft

Remove the two cap screws irom each main bearing cap and remove
the three main bearing caps {hg, 41). Lift the crankshaft from the
cylinder block.

A - SUNGER, OIL, FRONT ™ 7371161
B - SPACER, CRANKSHAFT - 77414U
C - GEAR, CRANKSHAPT -77 4] 4} 5
D - KEY, WOODRUFF ~~ 1 24552
I ™ WASHER, THRUST ~ 7371 160
p^ SHIM, FRONT -737 12 26
G ~ SEARING, MAIN, FRONT, UPPER - CG8-20500
H - PIN, DOwa, BEARING - 7371229
J - BEARING, MAIN, CENTER, UPPER - CO8-20502
K -SEARING, MAIN, SEAR, UPPER - CGB-20504
i ™ BOif , FLYWHEEL - WO-d3 2 1 57
M - CRANKSHAFT - 774447^
. N:--::PIN, dowel, F IYWHEEL ^ WO-632.1 56
: ;>■ ^ SEAmNG,^ -MAIN, iSAR,, LOWER- ~ CGB.205<3-5 '
a »* SEARING, MAIN, CENTER, LOWER ^ CG6-20503
t - iiARING, MAIN, f RONT, LOWER ™ CGB-20501

RA PO 358005

Figure ^S. Crankshaft — exploded view.

Section V. REBUILD OF CYLINDER BLOCK, HEAD, AND OIL PAN

42. Cleaning

Strip off all old gaskets and sealing compounds from all machined
surfaces. Remove plugs and clean all oil passages in the cylinder
block with steam or compressed air. Scrape the carbon from the cylin-
der block and head. Clean the cylinder block, head, and oil pan
thoroughly with dry-cleaning solvent or volatile mineral spirits paint
thinner.

43. Inspection and Repair

a. Oil Pan (fig. 38) . An oil pan with stripped threads in the drain
plug opening, or an oil pan that is badly dented or deformed, must be
replaced.

&. Cylinder Head (fig. 41). A cracked or warped cylinder head,
or a cylinder head with stripped threads in the spark plug holes, must
be replaced.

<?. Cylinder Block (fig. 41) . A cracked or damaged cylinder block
must be replaced. All loose expansion plugs (figs. 28 and 29) or dam-
aged studs must be replaced {d below.) A scored, ridged, discolored,
or excessively worn front camshaft bearing (fig. 37 and par. 154)
must be replaced {e below). Measure the other three camshaft bear-
ings with a micrometer caliper. If the bearings are larger than speci-
fied (par. 154), the cylinder block must be replaced. Measure the
cylinder bores with a micrometer caliper and dial gage. If any cylin-
der bores are out-of -round, tapered, or worn beyond wear limits (par.
149), the block must be rebored to next oversize or replaced. Pitted,
burned, or nicked valve seats must be reseated. Check the clearance
of the valve guides with new valves. If the clearance exceeds that
specified (pars. 165 and 156), the valve guides must be replaced (/ be-
low) . If the clearance exceeds 0.003 inch between valve tappet and
valve tappet bore, ream bore to 0.004-inch oversize and install 0.004-
inch oversize valve tappets when assembling engine. If valve tappet
bore will not clean up at 0.004-inch oversize, the cylinder block must
be replaced.

d. Replace Studs (fig, 58). Kemove all damaged studs with a
standard stud puller. To remove a broken stud, center punch the top
of the stud and drill approximately two-thirds of the length of the
broken stud with a small drill, then follow up with a larger drill.
However, the drill selected must leave a wall thicker than the depth of
the threads. Select an extractor (EZ-Out) of the proper size, insert
it into the drilled hole, and screw out the remaining part of the broken
stud. Install the studs with a standard stud driver. Drive all studs
until no threads show at the bottom of the unthreaded part of the
studs.

e. Replace Camshaft Bearing. Drive a punch between the cam-
shaft bearing and cylinder block (fig. 44) , and tap the camshaft bear-
ing out of the cylinder block. To install the camshaft bearing, drive
it in place with a fibre block, making sure the oil hole in the bearing is
in line with the oil passage in the cylinder block. Stake the camshaft
bearing in place with a punch (fig. 45) . Line ream the camshaft front
bearing to conform to serviceability standards (par. 154).

liiiiiiiiiBiiiiiiiiiBilii

c ™ BiocK, cyf^^iiilliiiii

mmmmmmMmm

Figure 44' Removing camshaft J)earing from cylinder Mock,

/. Replace Valve Guides. Remove the guides using valve-guide
remover and replacer 41-R-2379-25. When installing valve guides,
drive all intake and exhaust valve guides into the block using valve-
guide remover and replacer 4^1-R-2379-25 (fig. 46), leaving a dis-
tance of 1 inch from the top of the guide to the top of the cylinder
block for exhaust- valve guides, and a distance of 1%6 inches for the
intake-valve guides.

Figure 45. Staking camshaft hearing in place.

Figure ^6. Installing valve guides using adapter 708S262 and driver t08S26L

Section VI. REBUILD OF WATER PUMP
44. Disassembly

Pull the water pump bearing retaining ring from the water pump
(fig. 47). Eemove the water pump impeller using puller 7083446
(fig. 49). Eemove the water-pump seal and washer. Press out the
water pump bearing and shaft assembly and water pump pulley from
the water pump body as a unit. Remove the water pump pulley
(fig. 48) from the water pump bearing and shaft assembly using puller
41-P-2958-55).

A - PiJUXy, f AN AND WATER t»UMf^ - 7372558

B - SHAFT, W- BEARING, ASSY - 737 J8U

C "~ RfHG, RETAJNING - WO-*36298

~ BODY, WATER PUMP - 7372S07

£ ~ WASHiS ^ WO-800003

f ^ SeAt~WO-80r048

G-~tMPEUER-^737!383

« -^ GASKET, WATER POMf* TO CYLINDER 6lOCK-»Wa637053

iK^^ $5790|:

Figure 47. Water pump — exploded view.

45. Cleaning

Clean all parts thoroughly in dry-cleaning solvent or volatile min-
eral spirits paint thinner.

46. Inspection and Repair

a. Water Pump Bodt (fig. 47) . A cracked or damaged water pump
body must be replaced. Ref ace seat using ref acer 41-Er-2329-700 (figs.
50 and 51).

h. Water Pump Impeller (fig, 47) . A water pump impeller that is
cracked or that has a broken fin must be replaced.

G. Water Pump Pullet (fig. 47). A distorted or damaged water
pump pulley must be replaced.

WRENCH

f:^?!^^fKSiS^.ft«f||ff^S;

:J^m

PULLEY - 7372550

Figure 48. Removing fan and water pump pulley using puller /fl-P-29o8-15.

d. Water-Pump Beaking and Shaft Assembly (fig. 47). Rotate
the water pump bearing ; if the bearing binds or has a tendency to stick,
it must be replaced. Bearings that have side or end play, must be re-
placed.

47. Assembly

Press the front (short) end of the water-pump bearing and shaft
assembly into the water pump pulley (fig. 47) . Press the pulley and
bearing and shaft assembly into the front end of the water-pump body
until the groove on the bearing is alined with the small slot in the
body. Dip a new seal assembly and seal washer in hydraulic brake
fluid and install them in the water-pump impeller. Press the shaft
into the impeller until the end of the shaft is flush with the end of the
impeller. Install the bearing retaining ring.

)ii§^i^l:j:^■f^^y}4ig^^^

Figure 49. Removing water pump impeller using puller 108SHQ.

0OOY, WATfiR ?UMP

um:-^^9om-

Figure 50. Water-pump refacing tool 4f-R-S3^0-70(?,

Figure 51. Ref<icing waier-pump-dodp seal surface using refacer .^l^R-232.

953383—31 5

Section VII. REBUILD OF CONNECTING RODS AND PISTONS

48. Disassembly

Eemove the piston rings (fig. 42) using a standard ring remover.
Remove the piston pin lock bolt and push the piston pin out of the
piston.

49. Cleaning

Scrape the carbon from the carbon groove in the dome, ring grooves
in the piston, and from the dome. Remove all foreign matter from the
oil holes in the oil ring (bottom) groove. Clean all parts in dry-
cleaning solvent or volatile mineral spirits paint thinner.

50. Inspection and Repairs

Pistons with cracks, scores, or damage of any kind must be replaced.
Determine the wear on the skirt of each piston at the bottom at right
angles to the piston pin. If the wear is 0.010 inch less than the original
size (par. 152), or if the piston is out-of -round more than 0.005 inch,
the piston must be replaced. Check the width of the ring grooves with
new rings and a feeler gage (fig, 52) . If the piston ring to piston
groove clearance exceeds dimension given in serviceability standards
the piston must be replaced. Measure the piston pin hole. If the
inside diameter of the piston pin hole is more than wear limit in serv-
iceability standards (par. 152), the piston must be replaced. Piston
pins worn to less than wear limit in serviceability standards (par.
153), must be replaced. Check the connecting rods for alinement,
using aliner connecting rod (figs. 55 and 56) . Bent or twisted con-
necting rods (par. 151) must be correctly alined. Damaged connecting
rod bolts must be replaced. Excessively worn, scored, discolored, or
pitted connecting rod bearings must be replaced.

51. Fitting Pistons

(fig. 58)

The normal clearance of the piston to the cylinder bore is approxi-
mately 0.003 inch, see serviceability standards (par. 152). Place a
feeler gage %-inch wide and 0.003-inch thick into the cylinder bore,
making sure the feeler gage is long enough to extend down into the
bore the entire length of a piston. Attach piston fitting scale to
feeler gage. Push a piston into the cylinder bore with the T-slot in

the piston opposite the feeler gage. Pull up on the tension scale; if
more than ten pounds is required to pull the feeler gage from the
cylinder bore, the piston is too tight. Select a smaller piston. If
less than five pounds pull is required to remove the gage, the piston
is too loose. Select a larger piston. Mark the cylinder number on
each piston after fitting.

mno, PISTON ^ wo 1 %MU

.;fA.-l»D::
Figure 52. Checking piston ring to groove clearance.

Figure 53. Fitting piston pin.

RING, PISTON " WO.d37042

mtON -7372873

Figure 54. Checking piston ring fit.

ROD, CONNECTING™
7743/5) OR 7743752

PIN, PISTON -7371144

AMNER, CONNeCTtNG ROD

kAPD 357952

Figure 55. Checking connecting rod alinement for twist.

PIN, PiSTON

:Mmsy OR 7743752

ALINER, CONNECTING mo

kAPDZSnm!:

Figure od. Checking connvctifig rod alhiciitcnt for hcnd.

VAIVF, CHAmCA%t VfiNTtlATtNO - Al 3^6400
Hirni, PIP!:, \/4 n 3/4 192466
VAlVf, VENTiUltNC ■ 7%7S)7i
%Cm:W, COVKR wo- 445094

GASm WO-'$H75'

COVfcR, VAiVfc SPNiHC COMPARTMENT ?3?)?37

GA$KfT, COVIR

ELBOW, 1/4 JN
MALE, mm fND

OANKCAS£-8013}2

GASKIT, VINT mm TO
VAiy£ $PRiWG COMPARTMENT

covts 7Z-n777

BODY, V«NT, CKANKCASE ■^737121^

SC!«EW, COVER WO 6'*5093

figure 51. Valvc-spring-compartment cover and ventilating valves.

SCALE™ ^1-5-498

Figure 58. Fitthig piston in cylinder hore^ using scale and feeler gage.

06ir ■

HHHitt:^.' m

;^BS

^ : ;.|iM/ ;.'^^^^te:i^.''''' * ■■^^^* W^

^^^^o^MJSS^I

\ ...:■■'.:,..■ '^'^Bite... ^■■■^^^"'

. ,|«^^

''""■■*!*-.

■« J 'frN

« P ^>**-""'*'''"'^''*^^^^^: \

IHBB

^^^■HH

.^^ .:if|^^;iw-?»pr^^^;^^ /

'^SESSS^ZI

s.^^ ■■-" ^^.-^^■"' ^,^.^,_i..., .

^^^'^'^'^•--— ^^ .^i^^fe

Figure 59. Measuring piston-ring end cap using feeler gage.

52. Assemble Piston, Piston Pin, and Connecting Rod

When installing- connecting rods on piston, make sure the oil squirt
hole in the connecting rod is opposite the T-slot in the piston. If
assembled in this manner, the off -set on the connecting rods will be
in the correct position when installed in the cylinder block (par. 84).
Select a piston pin which can be installed in the piston with a light
"push" fit (piston temperature at 70° F.). Push the pin part way
into the piston pin hold (fig. 53), with the groove in the piston pin
facing downward. Hold the connecting rod in line with the piston
pin hole, and push the pin through the connecting rod into the other
side of piston. Install and tighten the piston pin lock bolt in the
connecting rod.

Note. The slot in the piston pin should be centered with the piston-pin-lock
bolt, to prevent piston pin from scoring cylinder side walls.

53. Fit and Install Piston Rings

Using a connecting rod with piston attached as a rammer, so the
ring will be square with the cylinder wall, insert a new piston ring in
the cylinder bore, a distance equal to the length of a piston. Measure
the piston ring end gap with a feeler gage (fig. 59) . If the gap is less
than minimum specified in serviceability standards (par. 152), remove
the ring and file with a fine cut file until the correct gap is obtained
(par. 152) . If end gap exceeds maximum specified (par. 152) , use an
oversize ring. Repeat the same procedure for all piston rings. KoU
the new piston ring around its particular groove in the piston (fig.
54) . The ring should roll freely and not have a clearance greater than
specified in serviceability standards (par. 152) (fig. 52). Repeat the
above procedures on each piston ring. Install the piston rings on the
piston using a piston ring applier (fig. 60), making sure that edge
marked "TOP" on both compression rings are toward the top of piston,
and ring having beveled edge is installed in the top groove.

Section VIII. REBUILD OF CAMSHAFT

54. Cleaning

Clean the camshaft, camshaft gear, camshaft gear washer, camshaft
thrust washer and thrust plate in dry-cleaning solvent or volatile
mineral spirits paint thinner.

APPUER, PISTON R!NG^ 41 -A- 3 29-500

RING, PISTON- WO- 11661 6

PiSTON ™7372873

RAPD 357957

Figure 60. Installing piston rings.

55. Inspection and Repair

A camshaft with excessively scored or damaged cams, or with worn,
corroded, scored, or discolored journals must be replaced. Inspect
the camshaft oil pump drive gear. If the teeth are worn, broken, or
chipped, the camshaft must be replaced. Measure the four camshaft
journals (fig. 37), and record the readings. If readings do not con-
form to size specified in serviceability standards (par. 154), the cam-
shaft must be replaced. Should it be necessary to replace the gears,
due attention must be given to both the end float of the shafts and
running clearance of the gears. End float of the camshaft is deter-
mined by the running clearance between the face of the camshaft gear
and the thrust plate (fig. 37) , mounted on the crankcase. The stand-
ard clearance is 0.004r-0.007 inch which is determined by the thickness
of the thrust plate spacer. Generally this clearance will change little
through wear or even when a new gear is installed. Should a check
indicate too little end float, place a shim of suitable thickness between
the gear hub and the spacer. Too much end float may be corrected
by dressing off the spacer until required thickness is obtained. Use
a micrometer to measure the thickness of both the thrust plate and the
thrust plate spacer. The thickness of the washer should be approxi-
mately 0.006 inch greater than that of the thrust plate. When the
gear and washer are mounted on the shaft and drawn up solidly with
the mounting screw, the parts will be drawn together to provide the
correct end float of 0.004 inch. When the spacer is installed, be sure
that the face having the beveled edge is placed toward the cylinder
block.

Section IX. REBUILD OF VALVES AND VALVE SPRINGS

56. Rotator-Type Exhaust Valve

(%. 61)

The rotator type exhaust valve used on this vehicle consists of a
special valve spring retainer, valve cap, two retainer locks, a spring
seat, and a special hard faced valve. A standard valve spring is used.

57. Operation of Rotator-Type Exhaust Valves

At the beginning of the valve lift, the valve tappet first pushes the
valve cap (fig. 61) through the nominal clearance, taking the spring
load off the valve before it opens. This action results in the valve
being free once it starts to open and remaining free until it closes,
permittin,g the possibility of slight valve rotation during each cycle.

58. Cleaning

Scrape the carbon off the valve heads and stems. Clean the valves
and valve springs thoroughly in dry-cleaning solvent or volatile

mineral spirits paint thinner,

59. Inspection and Repair

Yalves with bent or scored stems must be replaced. Measure the
outside diameter of each valve stem. If measurement is less than
specified in serviceability standards (pars. 155 and 156) replace
valves. Pitted, corroded, or burned valves must be refaced. Valves
that are burned, warped, or pitted, and will not clean up with a slight
cut of the grinding wheel, must be replaced. When the rotator-type
exhaust valves are removed for rebuild, always keep each exhaust
valve and keeper assembly (valves spring retainer, locks, and valve
cap) together to minimize the amount of refitting necessary when
measuring the valve-cap-to-valve clearance. If part of one assembly
is worn or damaged or lost, it can be replaced with a new one, but
clearance must be checked. Valve-spring-retainer locks in general
are the only parts which may have to be replaced because of wear.
However, since the wear is normally light and only on one side, they
may be re-used. If re-used, they should be installed, with the worn
side away from the valve tip, so that the unworn surface is used for
subsequent running. If due to excessive wear or breakage, valve-
spring-retainer locks must be replaced ; always install two new locks.
Measure the free length of each valve spring ; if less than 2% inches
in length the spring must be replaced. Check the tension of each
valve spring (fig. 63) using tester 41-T-1600. If the valve spring
tension registers less than 50 pounds when the valve spring is com-

pressed to Qi/ig inches or 116 pounds when compressed to 1% inches
in length, it must be replaced. Measure valve-cap- to- valve clearance
using valve cap clearance gage 41-G-500-90 (fig. 62). Assemble
the exhaust valve, spring, retainer, locks, and cap in the tester, with
the cap seating against the end vertical surface of tester. Push cam
handle down toward base of ga^e, this will cause rotator valve-cap to
force valve keys away from the valve-stem lock-groove allowing valve
to rotate freely. Adjust dial gage so that the prong contacts the top
of valve. Push the valve stem into the cap until it seats, note reading
on indicator. Pull the valve stem forward (out of cap) until the
lock groove on the stem contacts the locks and note reading. The
difference between the two readings is the valve-cap-to-valve clear-
ance. If clearance is less than 0,003 inch, grind off the valve stem
end. If clearance is more than 0.003 inch, polish off the rim of the
valve cap using abrasive cloth. When correct clearance is attained,
remove valve from gage and keep the parts together until installed in
the engine.

Section X. REBUILD OF VALVE TAPPETS

60. Cleaning

Clean the valve tappets thoroughly with dry-cleaning solvent or
volatile mineral spirits paint thinner.

61. Inspection and Repair

Cracked, scored, or excessively w^orn valve tappets (fig. 61) must be
replaced. Valve tappets, or valve tappet adjusting screws (fig. 61)
with worn or damaged threads, must be replaced.

62. Disassembly

Unscrew the valve tappet adjusting screw from the tappet.

63. Assembly

Screw the valve tappet adjusting screw approximately three-
quarters of the way into the valve tappet.

■iii

^iiM::3i:

Figure 61. Rotator-type exhaust valve— eicploded view.

IHifcfilii

.;:/;;,^j;';-;;./:.::::;:;fr-;v;:..';:^

Fiuure 62. Checking ei hamt valve4o-vulve cap clearance with gage 41-0^500-90.

STONO, SfAlVi ..-737123 5

ir^lffi ■■■ -^i rl^OO

mm 3S7f$^

Figure GS. ChecMny teiiKion of valve spring.

Section XI. REBUILD OF OIL PUMP AND OIL STRAINER

64. Disassembly

d. Oil Pump. Remove the cap screw and lock washer that secures
the oil pump assembly to the cylinder block, and remove the oil pump
assembly (fig. 32). File either side of the driven-gear pin (fig. 64),
until the pin is flush with the driven-gear hub. Drive the pin out of
the sleeve and shaft using a small punch and remove gear. Remove
the relief -valve-spring retainer, gasket, spring, and plunger from the
housing. Remove the five cap screws that hold the cover to the hous-
ing and remove the cover. Remove the cover gasket, rotor, and shaft
assembly.

I H {2| t^ N MTi

GASKET, Oil PUMP TO CYUNDER BlOCK> 7372587
GEAR, DRIVE, PUMP ~« 7744333
BODY, Oil POMP - WO-649872

I^SCRHW, EXT-TEfTH lOCX WASHER, ™ 420992

SHAFT, W/R0T08S. ASSY -~ W064 1742

PIN, 5/32 X- 31/32
-7371279

PLUNGER, PRESSURE REUEF
VALVE ^7371 275

SPRING, PLUNGER - 7372586
GASKET/ RETAINER - 7371 270

RETAINEI?, SPRING -^7371271

RAPD 357394

Figure 64. Oil pump — exploded view.

h. Oil Strainer. Eemove the cotter pin that secures the oil strainer
to the support, and remove the strainer (fig. 38) . Straighten the four
tabs on the strainer, and remove the screen.

65. Cleaning

Clean all parts and drilled passages thoroughly with dry-cleaning
solvent or volatile mineral spirits paint thinner, and blow the oil
strainer screen and all oil passages in the oil pump and oil strainer.

66. Inspection and Repair

A cracked or damaged oil pump housing or cover must be replaced.
Match the rotors together with one lobe of the inner rotor pushed as
far as possible into the notch of the other rotor (fig. 64) ; if the clear-
ance between the lobes of the rotors (fig. 65) is greater than wear limit
specified in serviceability standards (par. 157), replace both rotors.
Measure the clearance between the outer rotor and the pump housing
(fig. %%). If the clearance is greater than wear limit specified in
serviceability standards (par. 157) , replace the pump housing. Check
the cover to be sure the inner surface is not rough or scored and that it
is flat within 0.001 inch, tested with feeler gage (fig. 67). Measure
length of the rotors, which must be within 0.001 inch of each other.
An oil pump driven gear with broken or chipped teeth must be re-
placed. Compress the relief -valve spring to ly^g inches (fig. 63) , using
tester 41-T-1600. If the tension is less than 71/2 pounds (par. 157),
the spring must be replaced. Replace a broken, distorted or cracked
oil-strainer support (fig. 38).

67. Assembly

a. Oil Strainer. Place the screen in the oil strainer (fig. 38).
Place the sump on the strainer, and bend the four tabs to lock the
sump in place. Slide the support onto the strainer, making sure the
tongue on the support is in the recess. Install a cotter pin in the
support.

h. Oil Pump. Assemble the rotors in the pump housing and in-
stall the cover without the gasket. When the cover screws are tight-
ened to normal tension, there should be interference between the rotors
and the cover making it impossible to turn the pump shaft by hand.
Remove the cover and replace it with the gasket in position which
should free the rotors and shaft. Tap the driven gear onto the shaft
with the gear toward the oil pump until there is a 0.0313-inch clearance
between the gear and the pump housing. If installing a new shaft,
drill a hole for the pin. Install a new driven gear pin through the
gear and shaft. Peen both ends of the driven gear pin. After as-
sembling the gear on the shaft, check the running clearance between

the gear and pump housing with a feeler gage (fig. ^6). This clear-
ance should be from 0.003 to 0.010 inch. Drop the oil relief plunger
and spring into the opening in the oil pump housing (fig. 64). Place
a new gasket on the oil relief spring retainer, and install and tighten
the retainer.

^BODY, Oil PUMP
WO-801761

RA PD 357949

Figure 65. Checking clearance hetween lohes of rotors.

SNAfT W/ROTORS"' ^1
^ WOh$41742

SODY, OIL PUMP
~~WO-649a72

tA.PD. 35796^.

Figure 66. Checking rotor-to-pump-housing clearance.

GAG'S. f^LEt

COV£lt SO^Y . ™77 4 4 33.2

Figure 67. Checking oil pump cover for flatness.

Section XII. REBUILD OF CRANKSHAFT

68. Cleaning

Clean out the drilled holes on the crankshaft journals with a piece
of wire. Clean the crankshaft thoroughly with dry-cleaning solvent
or volatile mineral spirits paint thinner.

69. Inspect Crankshaft Main Bearing Journals

(fig. 43)

If worn or scored, the crankshaft must be replaced or journals re-
ground. Measure the outside diameter of each main bearing journal.
If the diameter is less than that specified in serviceability standards
(par. 150) , the crankshaft must be reground to 0.010-, 0.020-, or 0.030-
inch undersize, whichever the case may be. Light scores and scratches

1 1 _i J ii i:„i»_j ,„:j.i„ «, — „i^+i^

call ue iiuiiba mux liikhi poiisiieu. witii i;iui;us (jiuuii.

jLj. mam u^^tiAxxxg

journals will not clean up at 0.030-inch undersize the crankshaft must
be replaced. If a new crankshaft or flywheel is being used, it must
be fitted as outlined in paragraph 74.

Section XIIL REBUILD OF FLYWHEEL

70. Cleaning

Wash the flywheel thoroughly in dry-cleaning solvent or volatile
mineral spirits paint thinner.

71. Inspection and Repair

A flywheel (fig. 68) with an excessively scored or worn friction
face must be replaced. A flywheel ring gear (fig. 68) with broken,
chipped, or excessively worn teeth must be replaced (pars. 73 and 74).
Measure the inside diameter of the main drive gear pilot bushing.
If more than 0.632 inch, it must be replaced (pars. 73 and 74). If a
new crankshaft or flywheel is being used, it must be fitted as outlined
in paragraph 74.

mn>--^^$$\

Figure 68. Flywheel, ring gear, and Maring.

72. Disassembly

Drive the main gear pilot bushing out of the flywheel. Heat the
flywheel ring gear until it can be driven off the flywheel.

73. Assembly

Clean the flywheel ring gear recess on the flywheel. Apply heat
evenly to the ring gear. When the ring gear is thoroughly heated,
place it on the cold flywheel, making sure it is firmly seated in its
recess. Drive a main gear pilot bushing in place with a fiber block.

74. Fit Crankshaft to Flywheel When Either Part Is New

Install the flywheel onto the crankshaft with the four flywheel bolts,
lock washers and nuts. Drill the tw^o tapered (stud) holes with a
3%4-inch drill, and ream the two holes with a %6-"i^li (0.5625 inch)
straight reamer. Install the two bolts that are supplied w^ith each
crankshaft and/or flywheel.

Section XIV. REBUILD OF INTAKE AND EXHAUST MANIFOLDS

75. Disassembly

Eemove the four cap screws that secure the intake manifold to the
exhaust manifold and separate the two manifolds. Kemove the nut
and screw that secure the heat-control- valve shaft (fig. 69) . Remove
the counterweight lever, heat-control-valve lever, w^asher, and spring
off the shaft. Remove the crankcase ventilating and control valves
and primer line (fig. 32).

76. Cleaning

Scrape all the old gaskets and carbon from the manifolds. Wash
the manifold and parts in dry-cleaning solvent or volatile mineral
spirits paint thinner.

77. Inspection and Repair

Cracked or broken manifolds must be replaced. Damaged or
broken studs must be replaced (par. 43). An exhaust manifold with
a damaged heat control valve or shaft must be replaced. If the crank-
case ventilating valve fails to seat properly, it must be replaced. If
the ^-inch pipe threads are worn or stripped on the intake manifold,
causing a leak at this joint, replace the manifold.

78. Assembly

Install the crankcase ventilating and control valves on the intake
manifold (iigs. 32 and 57) . Slide the heat control valve spring onto
the shaft (fig. 69), making sure the end of the spring is resting on
top of the stop. Slide the washer, counterweight, and control level
onto the shaft ; install the nut and screw through the counterweight.
Place a new gasket between the two manifolds and install the four
cap screws and spring stop. Install primer fuel line.

A »- SCREW, lEVER, COUNTERWBGHT- WO'5272

B^-KEY, HEAT CONTROl VAlVE LEVER -737 1396

C- SHAFT, HEAT COHTSOl VAiVE~-737l391

0- WASHER, H£AT COHTtOL VAlVg SPmNG -7371 390

i-lEVER, COUNTER WSGHT, HEAT CONTROL VALVE -7371392

F -SPRING, HEAT CONTROL VAiVE- 7372565

G-STOP, HEAT CONTROL VALVE SPRING -737 1 395 ^^ ^^ 358006

Figure 09. Manifold heat control valve.

Section XV. ASSEMBLY OF ENGINE FROM SUBASSEMBLIES

79. Install Valves

Place a valve tappet and tappet adjusting screw in each valve tappet
bore. Slide the camshaft into the cylinder block. Install a valve
spring and valve spring retainer on each tappet (fig. 61), making
sure the closed coils of the valve springs are against the cylinder
block and properly seated. Install the valves in their respective valve
guides. Compress the valve springs on all valves that are in closed
position, using valve lifter, and install the valve spring retainer locks
{&g. 70). Turn the camshaft to close the other valves, and install
the valve spring retainer locks on the rest of the valves.

A ~~ TAPPET, VAtVE - 7372585
B - SCREW, ADJUSTING, VALVE CIEARANCS
C - RETAINER, VAIV6 SPRING -7371236
D ™ UFTER, VAtVE ^ 4M-1410
£ ™ SPRING, VAIVE - 7371235
F - BLOCK, CYDNDER - WO-800100
G - REPLACES ~ 4]'k-2^P^'$4

7371258

m-rt>-nm^;^

Figure 10. Installing valve spring retainer locks, using lifter 41~L-1410 and

replacer Jfl-R~2398

Note. Install the valve cap on rotator-type-exhaust-valve stems (fig. 61)
while the spring is compressed.

80. Adjust Valve Tappets

Turn the camshaft until No. 1 valve is in the closed position, and
the tappet is on the heel of the cam. Hold the valve tappet with one
wrench and turn the valve tappet adjusting screw with another
wrench (fig. 71) clockwise or counterclockwise until 0.016-inch clear-
ance is established between the valve and the valve tappet adjusting
screw (pars. 155 and 156) . Repeat the same procedure on each valve.
Install valve-spring-compartment cover and vent body. Connect
crankcase vent line to cover and to ventilating valve elbow.

iiiliiiiii^iiSiiiiiiiSiliiiiMii^

W§ggg§Sig§M$l^ '.':■'■■ ^^ ^^ 358003 ■

Future 11. Adjusting valve tappets,

81. Install Crankshaft

If a new crankshaft or flywheel is being used, refer to paragraph
74 and 85. Install the three upper halves of the main bearings in the
cylinder block (fig. 41). Press the crankshaft rear-main-bearing
packing into the recess provided at the rear main bearing (fig. 72)
and in the rear-main-bearing cap (fig. 72) . Cut the ends of the crank-
shaft packing flush with the crankcase and with the bearing cap. In-
stall the four bolts and the two tapered studs in the flywheel flange
on the crankshaft. Install the three lower halves of the main bearings

in the three main bearing caps. Oil the main bearing inserts with
a light oil. Position the crankshaft in the cylinder block. Install
the front and center bearing caps, and tighten the bolts until they
are just snug. Coat the rear-bearing cap with joint sealing compound
on both sides and top. Install the rear-bearing cap in the cylinder
block. Tighten the six main-bearing bolts with a torque wrench (65
to 70 Ib-ft) . Slip the rear-bearing-cap packing into the hole on each
side of the rear-main-bearing cap, leaving i/4-inch of the packing to
protrude from the crankcase (fig. 72) (par. 143) .

RAK> Z57902

Figure 12. Installing rear-hearing-nap pacMng.

82. Fit Crankshaft

After installation of crankshaft, check the running clearance. Place
an 0.002-inch test shim between the shaft and the shell. With the
bearing cap nuts drawn up to the recommended 65-70 Ib-ft torque,
the shaft should either be locked or there should be a drag when it
is turned by hand proving that the clearance is correct.

Caution: Do not overlook removing the test shim.

83. Check Crankshaft End Play

The standard end play of the crankshaft is 0.004 to 0.006 inch which
is adjusted by shims placed between the crankshaft thrust washer
and the face of the front main bearing. Check clearance with feeler
gage (fig. 73). To adjust end play, it is necessary to remove the
crankshaft gear using puller 41-P-2956-4 (fig. 40), and the thrust
washer. When installing the washer, be sure the side with the inner
beveled edge faces the front bearing.

Caution: Never file a main bearing cap or install shims between the
cap and block as roundness and alinement of bearings will be
destroyed.

84. Install Connecting Rods and Pistons

Piston assemblies must be installed in the cylinders to which they
are fitted (par. 51). Oil the piston rings and install a ring com-
pressor on the piston rings (^g. 74). Place the No. 1 connecting rod
and piston assembly in the No. 1 cylinder so that the short end of
the offset (fig. 75) on the connecting rod is toward the nearest main
bearing. With the T-slot of the piston facing toward the camshaft
side of the engine, and the oil squirt hole in the connecting rod facing
toward the oil-filler-pipe side of the engine, tap the piston down into
the cylinder with the handle end of a hammer (fig. 74). Place one-
half of a connecting rod bearing in the connecting rod, and the other
half in the connecting-rod-bearing cap. Coat the connecting rod
bearings with a light film of oil. Connect the rod to the crankshaft
and install, but do not tighten the two connecting rod nuts. Repeat
the same procedure when installing the other rods, making sure the
short end of the offset (fig. 76) on each connecting rod is toward
the nearest main bearing and the oil squirt hole faces toward the oil-
filler-pipe side of the engine with the T-slot of the piston facing to-
ward the camshaft side of the engine. Tighten all the connecting-rod
nuts to 50 to 55 lb- ft torque using a torque wrench. Install a jam
nut on each connecting rod bolt. Turn the jam nut down on the bolt
until seated against the connecting rod nut, then turn one complete
turn.

Mgure 73. Checking crankshaft end play,

85. Install Flywheel

If installing a new flywheel or crankshaftj fit the crankshaft to the
flywheel, as outlined in paragraphs 74 and 82. Fasten the engine rear
plate temporarily to the engine with two bolts. Turn the crankshaft
until the No. 1 and No. 4 pistons are at top center. Place the flywheel
on the crankshaft flange so that the letters "TC" on the flywheel are
alined with the index mark at the center of the timing hole (fig. 76) in
the engine rear plate. Install the timing gears, and position them so

that the indent marks on the gears are opposite each other (fig. 77) .
Install and tighten the six lock washers and nuts on the flywheel with a
torque wrench to 36-40 Ib-ft. Check run-out on the flywheel with a
dial gage. If the run-out exceeds 0.008 inch at the outer edge, the
flywheel or crankshaft flange must be ref aced.

Figure 74. Installing piston and connecting rod asseniMy in cylinder J>locTc.

Figure 15. Position of connecting rod offset and oil squirt hole when installed.

86. Install Clutch Disk and Pressure Plate

(fig. 78)

Apply a good coating of No. 2 general purpose lubricating grease on
flywheel pilot bearing. Hold the clutch disk on the flywheel with short
side of hub toward flywheel and install a clutch pilot tool in the flywheel
and the disk. Hold the pressure plate on the flyw^heel and install, but
do not tighten six lock washers and cap screws. Tighten the six lock
washers and cap screws evenly to prevent bending the pressure plate
cover. Remove the clutch pilot tool.

Figure 76. Ignition timing marks on fiijtvheel.

87. Install Camshaft Timing Gear

Eemove the camshaft gear. Place a gasket and the engine front
plate on the engine and install the three cap screws and two nuts and
lock washers. Turn the crankshaft until No. 1 piston is at top center
(fig. 36) . Install the thrust plate and spacer (fig. 40) , making certain
the beveled edge of the spacer faces the camshaft. Place the camshaft
timing gear on the camshaft, making certain the zero "0" marks on the
camshaft and crankshaft timing gears are opposite each other (fig. 7),
Insert the camshaft timing gear washer, lock nut, and retaining bolt.
Tighten bolt.

88. Install Timing-Gear Cover and Crankshaft Pulley

(fig. 41)

Place a gasket on the timing-gear cover ; install oil seal in recess pro-
vided in cover. Place spacer and oil slinger on shaft. Install the
cover on the engine.

Note. Do not tighten nuts down tight as this may interfere with installation
of crankshaft pulley.

Place crankshaft and fan belt pulley on shaft and tighten retaining
nut. Evenly tighten all engine front cover cap screws.

PIATE ENOiHE, FRONT -- 7372578

GEAR, CAMSHAFT -^774141^

€5EAIt>CRAHKSH^ "-7^41415 VfiMIHO GEAR MARKS RAH) 3^7913 |

■,.: . ■ . . ■ ........ ' . ■ ■ ■ . '.i

Figure 77. Timing gears.

953383—51-

PUTE, EHGtm SEAf? ~ 7375029

fLYWHEBL, W/R>NG GEAft^/^372582

PlATe, PRESSURE
7375073

SHAFT, INPUT ™ 7697566

COYER, TIMING HOIE » 737 ISO'S

'""^ir RAFD 357S9S

Figure 78. Installing clutch disk and pressure plate on flywheel.

89. Install Oil Pan

Hold a gasket and the oil strainer in place (fig, 38) and in>stall the
two lock washers and cap screws. Coat the bottom ( machined surface )
of the crankcase wdth grease, and install the oil pan gasket. Hold the
oil pan in place, and install all the lock washers and cap screws except
the six front cap screws. Hold the generator and fan pulley guard in
place and install the remaining six lock washers, gaskets, and cap
screws. Tighten all the oil-pan cap screws.

90. Install Cylinder Head

(%. 41)

Install a cylinder-head gasket on the cylinder block, making sure
trade mark on gasket faces cylinder head. Make sure there is no
foreign matter in the cylinders, and place head on cylinder block.
Install lifting eye on studs Nos. 1, 2, and 7 (fig. 79) . Install air intake
pipe on stud No. 5 (fig. 79) . Install oil filter bracket on studs Nos. 9,

10, and 15 (fig. 79). Install distributor-to-fuel-pump-vent-line hold-
down clip on stud No. 12 (fig. 79). Tighten the cylinder-head bolts
with a torque wrench from 65 to 75 lb- ft following tightening sequence
(fig. 79).

91. Install Intake and Exhaust Manifold

Place an intake and exhaust manifold gasket in place on the cylinder
block. Position the intake and exhaust manifold on the cylinder block.
Install nuts. Connect the crankcase ventilating valves (fig. 57) to the
intake manifold. Connect one end of the crankcase ventilation line to
the valve spring compartment cover and the other end to the ventilat-
ing valve elbow (fig. 57) .

^AH) SST969

Figure 79. Cylinder head-holts tightewmg sequettec.

92. Install Oil Pump

Place a finger on No. 1 spark plug hole, and turn the crankshaft
until No. 1 piston is coming up on compression stroke. Continue
turning the crankshaft until the timing mark "5°" on the flywheel
is alined with the index mark in the center of the timing hole on
the engine rear plate (fig. 76). Install the distributor in the cylinder
block (par. 98), temporarily. Set the rotor on No. 1 firing position
with the ignition points just breaking. Immerse the oil pump in a
container of oil (same grade as used in the engine), and turn the
inner rotor and shaft until the oil flows from the outlet hole in the
oil pump housing. Place a gasket on the oil pump and, with the wide
side of the slotted end of the shaft assembly up, install the oil pump
on the engine, making sure the slot in the oil-pump shaft engages with
the distributor shaft while the rotor is on No, 1 firing position with
ignition points just breaking. Install the three %6-inch cap screws
that secure the oil pump to block. Remove distributor.

93. Install Water-Outlet Elbow and Thermostat

(fig. 32)

Install the thermostat and retainer in the water-outlet elbow with
the bellows of the thermostat facing downward. Place a gasket on
the cylinder head and install the water-outlet elbow, lock washers,
and cap screws.

Section XVI. INSTALLATION OF ACCESSORIES

94. Install Water Pump

(figs. 27 and 32)

Hold a gasket and the water pump in place on the engine and
install the three lock washers and cap screws. Connect by-pass tube
between cylinder head and water pump.

95. Install Carburetor

(figs. 31 and 32)

Place a carburetor gasket and diffuser on the intake manifold
and install the carburetor, accelerator-return- spring clip, lock
washers, ventilating- valve -control-cable clip, and nuts. Install hose
between carburetor and air intake pipe. Install air-intake-pipe-to-
carburetor vent line.

96. Install Oil Filter

(figs. 2 and 27)

Hold the oil filter in place, and install and tighten the two cap
screws. Connect the oil-filler-pipe bracket to the oil-filter bracket
with a cap screw. Connect inlet line to the elbow fitting located on
the left side of the engine in front of the fuel pump opening. Connect
outlet line to timing gear cover. Connect oil filler pipe to ventilating
valve hose (fig. 38).

97. Install Fuel and Vacuum Pump

(fig. 30)

Insert two mounting screws and washer in fuel pump mounting
flange holes, using screws as a guide place gasket on fuel pump ; in-
stall rocker arm link spacer and gasket. Hold the entire fuel pump
in place on engine, making sure the fuel pump rocker arm is on top
of camshaft. Tighten the mounting screws that secure the fuel
pump to cylinder block. Install carburetor to fuel pump line. Install
two vacuum lines on lower portion of pump.

98. Install Distributor

(fig. 33)

Place a thumb over No. 1 spark plug hole, and turn the crankshaft
until No. 1 piston is coming up on compression stroke, and the timing
mark "5°" on the flywheel is alined with the index line on the engine
rear plate. Install the distributor on the engine, and rotate the rotor
until the distributor shaft engages with the oil pump shaft. Install
the cap screw in the distributor hold- down clamp, and turn the dis-
tributor until the points are just breaking. Tighten the bolt in the
distributor hold-down clamp.

99. Install Pin

(fig. 32)

Hold the fan in place on the w^ater pump pulley, and install the
four lock washers and cap screws.

100. Install Generator

(fig. 33)

Install the generator bracket on the cylinder block with two lock
washers and cap screws. Install the generator on the engine, making
sure there is a flat washer on each side of the rubber bushing in the
generator bracket and engine front plate. Install a flat washer, lock
washer, and nut on the generator front mount. Install a flat washer,
lock washer, and nut on the generator rear mount. Install belts and
adjust tension.

2Vo^e. Never install a new and an old hclt.

101. Install Starter

(figs. 26 and 33)

Hold the starter in place on the clutch housing and install and
tighten the two cap screws on the clutch housing. Hold the starter
mounting bracket in place on the engine and install a lock washer, flat
washer, and cap screw.

Note. Do not tighten the cap screw.
Install and tighten a lock washer, flat washer, and cap screw in the
starter and starter support bracket. Tighten the cap screw in the
starter support bracket.

102. Install Spark Plugs and Cable

Install the distributor cap on the distributor. Install the spark
plugs and new spark-plug gaskets in the cylinder head. Connect the
spark-plug cables.

103. Install Accelerator Linkage

(fig. 31)

Install the accelerator (throttle linkage) on the engine with two
lock washers and cap screws. Connect the accelerator linkage to the
carburetor throttle lever with a cotter pin, making sure flat washer is
in place. Connect the accelerator return spring to the accelerator
return spring clip.

Section XVII. RUN-IN TESTS AND ADJUSTMENTS

104. Accessories

Tests and adjustments of accessories are outlined in the pertinent
operator's manual and pertinent maintenance technical manuals
(par. 1).

105. Preparation for Run-in

Install the engine to a dynamometer. Pre-oil the engine, forcing
oil under pressure into the oil system. This insures adequate lubri-
cation to the engine parts until the engine pump supply reaches them.
If no pre-oiling equipment is available, fill all external oil lines with
the proper grade of oil.

106. Engine Run-in

a. General. A rebuilt engine will be started and run-in in accord-
ance with table II listed in / below and with instructions given in TB
OKD 215.

h. Warm-up Eun Before Adjustments. Fill the engine with oil
to the "Full" mark on the bayonet-type oil gage using OE-10 engine
oil. Eun the engine for 15 minutes at 1,000 rpm, no load, to warm up
engine. Stop the engine and perform operations in c and d below.

c. Distributor Adjustment.

(1) Adjust breaker point gap to 0.020 inch.

(2) Adjust ignition timing to 5° BTDC at 600 rpm.

d. Carburetor Adjustment.

(1) Adjust idle adjusting screw for engine speed of 600 rpm.

(2) Adjust idle mixture to leanest setting for a smooth 600 rpm
idle (TM 9-801).

e. Warm-up Run After Adjustments. Start engine and run for
perio'd of time and load as indicated in period 1 of table II (/ below) .
Eecord the oil and w^ater temperature, at the conclusion of this run,
on the test log (TB ORD 215) . Water temperature must be at least
120° F. and oil temperature at least 100° F. before starting period 2
run.

/. RiTN-iN Schedule.

Ifote, See TB ORD 215 for conversion of brake horsepower (BHP) to dy-
namometer scale readings. Dynamometers have various constants "K" or means
for determining load. The manufacturer's Instructions furnished with the
dynamometer will be followed.

Table II. Run-In Schedule

Period

Time minutes

Engine EPM

BHP load

1 . ^-

20
20
20
20
20
20
20
20
20
5
15
10

1,200
1,200
1,360
1,600
1,880
2,080
2,400
2,760
3,320
4,000
2,000
1,200

4 -

6 . -

7 _

8 -_- ^

3 hr3. 30 min.

g. Water and Oil Temperatures While Running in Engine.

(1) Water temperature should not exceed 160'^ F.

(2) Oil temperature should not exceed 220° F.
h. Record Readings at End of Each Test Period.

(1) Engine rpnu

(2) Dynamometer load reading.

(3) Brake horsepower (BHP).

(4) Oil pressure.
(6) Fuel pressure.

(6) Oil temperature,

(7) Water temperature.

(8) Cylinder head temperature.

(9) Manifold vacuum.

(10) Scale reading of oil weighing equipment if used.

i. Check: and Add Oil if Necessary. If oil weighing equipment
is not used, check the oil level at end of periods 3 and 7, table II.
Make the necessary additions in one pint increments. At the con-
clusion of run-in test complete and record on log the total amount of
oil used.

;. Record Air Temperature and Pressure Readings. Record ba-
rometer reading and wet and dry bulb temperature at end of period
5, table 11. Produced by Military Media, Inc.

RA f D 358020

Figure 80. Horsepoiver curve for Willys-Overlcmd model MG engine.

Section XVIII. ASSEMBLY OF POWER PLANT

107. Assembly of Clutch Housing to Transmission

(fig. 29)

Install the four lock washers and cap screws that hold the clutch
housing to the transmission. Working tlirough tlie large end of the
clutch housing, install the clutch control lever on the clutch release
bearing carrier, and on the ball joint located on the main drive gear
bearing retainer. Slide the lever cable through the hole in the hous-
ing, and connect the lever cable yoke end to the lever and tube assem-
bly with a clevis pin and cotter piu. Press the ball and socket joint
end of the lever inward, and slide the lever cable in place on the control
lever.

108. Installation of Clutch Housing and Transmission

i^g. 29)
Working with an assistant, assemble transmission and clutch hous-
ing to engine by sliding clutch housing onto dowel bolts on right and
left of engine rear plate ; install lock washers and nuts. Install re-
maining six bolts, lock washers and nuts, and tighten.

109. Installation of Transfer to Transmission

(fig. 29)

Place the transfer in position on the transmission. Install the bolts

100

that secure the transmission to the transfer case. Slide the mainshaf t
gear on the transmission mainshaft through the rear cover opening
on the transfer case. Install the flat washer, castellated nut, and
cotter pin that secure the gear to the mainshaft. Install a new gas-
ket and the rear cover on the transfer case.

110. Installation of Radiator

Insert radiator retaining rods on right and left sides of radiator.
With the help of an assistant, insert the rods in corresponding slots
on the engine (fig. 25). Install the radiator hoses and tighten hose
clamps.

111. Installation of Power Plant in Vehicle

(fig. 23)

Place radiator pads in place on frame. Install a suitable lifting
hook in the front lifting eye, mounted on the cylinder block. Lift
the power plant into the vehicle with a hoist, and lower it until trans-
mission and transfer case rest on the frame cross member. Force the
rear of the engine to the left to connect the clutch linkage at the ball
stud. Kemove lifting hook.

112. Installation of Transmission to Frame

(fig. 21)

Install the transmission hold-down bolt, nut, and lock washer se-
curing the right side of transmission and transfer case to the frame
cross member. Tighten the two nuts on the right and left sides of
the transmission, noting that the slotted brackets are secure. Tighten
the two hold-down bolts in each front engine support mounting
bracket.

113. Installation of Hand Brake Cable, Clutch Cable, and

Engine Stay Cable

Slide the engine stay cable through the bracket on the engine rear
plate (fig. 25) and into the ball socket connection; when tension is
even, tighten the bolts. Install the clevis that secures the clutch
release fork cable to the clutch shaft. Install the clevis pin that se-
cures the hand brake cable to the hand brake control lever at rear of
transfer case. Install the cap screw that secures the hand brake cable
clamp to the engine support plate.

114. Connect Speedometer Cable

Connect the speedometer cable at the transfer case (fig. 22),

101

115. Installation of Front and Rear Propeller Shafts

(fig. 21)

Install and tighten the U bolts, lock washers, and nuts that secure
the front propeller shaft to the driving flange on the transfer. Insert
rear spline shaft into universal joint sleeve and tighten seal and collar.

116. Installation of Poor Pan and Shift Levers

(fig. 17)

Hold the transfer shift levers in place and secure with fulcrum
pin (D, Q.g. 20). Insert the gear shift lever, gear shift lever spring,
and lever spring washer into the gear shift housing. Tighten the
gear shift housing cap. Slide rubber boot down into position on gear
shift housing. Tighten the 24 cap screws and internal toothed wash-
ers. Install and tighten the clamps on the gearshift lever rubber
boot.

1 1 7. Installation of Electrical Cables

Connect the starter cable, auxiliary power receptacle cable, and
starter-to-regulator cable to the starter. Connect the field, armature,
and ground cable plug to the generator.

118. Installation of Air Cleaner

Place the air cleaner in place on the mounting bracket ; secure the
four wing screws in place. Slide the air cleaner hoses onto the metal
tubes and tighten the hose clamps. Connect windshield wiper and
fuel-tank-to-air-cleaner vent lines at air cleaner. Connect air-cleaner-
to-dash- tee line at air cleaner.

119. Installation of Ventilating Valve Control Cables

Slide the valve-control-cable conduit through the hold- down
bracket, and the valve control cables through the collars on the valve
control arms (figs. 13 and 15). Push in the valve control handle
on the instrument panel. Pull the valve control levers forward as
far as possible, and tighten the set screws in the collars. Tighten the
bolt and nut securing the ventilating valve-control-cable conduit into
the bracket.

120. InstaHation of Choke and Throttle Controls

(fig. 31)

Slide the choke control conduit through the conduit clamp on the
carburetor, and the cable through the choke lever swivel screw. Push
in the choke control button on the instrument panel. Pull the choke
lever forward as far as possible, and tighten the swivel screw in the

102

collar. Slide the throttle control conduit through the conduit clamp
on the carburetor. Run the throttle control cable and conduit to the
left of the carburetor choke link and the carburetor. Run the throttle
control cable through the carburetor throttle shaft arm and screw as-
sembly. Push the throttle control cable on the instrument panel
all the way in. Tighten the screw on the carburetor throttle shaft
arm.

121 . Installation of Oil Pressure and Water Temperature Gage

Sending Units

Connect the water temperature gage sending unit at the right side
of the engine (fig. 11) . Connect the oil pressure gage line at the send-
ing unit on the left side of the engine (fig. 7) .

122. Installation of Radiator to Frame Cross Member

(fig. 10)

Install and tighten a lock washer and nut on each radiator mounting
stud.

123. Installation of Hinged Radiator Guard

(fig. 9)

Place radiator guard on front bumper and slide into hinged sockets.
Raise radiator guard to proper position and tighten the three nuts on
each side of radiator guard grill and connect the three head light
connectors at left head light (fig. 8) .

124. Installation of Radiator Brace Rod

i^g- T)

Install radiator brace rod in slot on rear of radiator and tighten
wing nut securing brace rod.

125. Installation of Battery

{^g- 6)

Install battery ground cable and close and fasten cover on battery
box.

126. Final Operations

Make sure the radiator and engine drain cocks are closed, and install
the specified coolant. Tighten the oil pan drain plug and fill the
engine with the specified amount and grade of oil. Start the engine.
If the oil pressure does not register immediately on the oil pressure
gage, stop the engine. Remove the oil pump relief valve retainer
and prime the oil pump.

103

CHAPTER 5
CLUTCH

Section I. DESCRIPTION AND DATA

127. Description

The clutch is of the single plate automotive type, composed of two
major units (fig. 81) ; the pressure plate assembly and the driven plate
or disk. The pressure plate is adjusted at the factory, and requires no
other adjustments, except where it is necessary to install new clutch
pressure springs, clutch springs, clutch fingers, or pressure plate
(fig. 82),

128. Data

Type Single dry plate

Torque capacity 144 Ib-ft

Clutch disk :

Make Borg and Beck

Facings 2, molded asbestos

Facing diameter Inside 5% in

Facing diameter Outside SVa in

Facing thickness 0.138 in

Pressure plate :

Make Auburn

Number of springs _ 6

Spring pressure at 1 9/16-in compressed length 180-195 lbs

Auxiliary spring pressure at 1.518-in compressed length 60 lbs

Section II. DISASSEMBLY OF PRESSURE PLATE

129. Removal of Clutch Adjusting Screw

Place the pressure plate and cover assembly in a press. Place a
wood block 2y2 inches square on top of the clutch levers (fig. 83) . De-
press the clutch levers, and remove the three clutch adjusting screws,
lock nuts, and washers (fig. 82). Kelease the pressure on the levers
slowly to prevent the pressure springs from flying out from under
the lever.

104

pi$K>; ; w/h:u.b/: assy;;- ;i^p-2d6f ; p:

f LAfI, PRESSUtg J

Figure 81. Clutch dWc and pressure plate.

RAPD 357914

130.

Removal of Clutch Pressure Spring Cups and Springs

(fig. 82)

Push the clutch pressure spring cups, springs, and spring retainers
from the pressure plate cover with a screwdriver or punch. Remove
the clutch pressure plate return clips from the cover.

131. Cleaning, Inspection, and Repair of Clutch

a. Cleaning. Clean all parts thoroughly using dry-cleaning solvent
or volatile mineral spirits paint thinner.
h. Inspection and Repair.

(1) Clutch pressure plate (fig, 82). A ridged, scored, radial
cracked, or burned pressure plate must be replaced.

(2) Pressure plate cover (fig. 82). A distorted pressure plate
cover or one with worn clutch levers must be replaced.

(3) Clutch pressure springs (fig. 82). Place each clutch pres-
sure spring (large) in a tension scale, and depress it to 1 9/16
inches (fig. 84) . If the spring tension is less than 180 pounds,

105

JNCHgS

e-coves wo-649971

C~-CUP, PRESSURE SPRING WO-800728
0-SPftiNG, Pg£SSUftE W0^649975
E-SPRING, AUXtliARY hi£5SUft£ WO~a02380
F-RETAJNER, AUXiUARY SPRING WO-802381
O-SCMW, ADJUSTING W0^64^976
H-CLIP, RETAiNER WO401698
i~.HUT, LOCK WO'649W2
K-WASHER WO-801641

Figure 82. Pressure plate diJ<ass<'mMed,

RAPD 357897

it must be replaced. The auxiliary pressure springs should
be depressed to 1.518 inches. If tension is less than 60
pounds, it must be replaced.

Section III. ASSEMBLY OF PRESSURE PLATE

132. Installation of Clutch Pressure Spring Cups and Springs

Install the clutch pressure spring cups and pressure springs in the
cover (%. 82), making sure the indentation of each cup is toward the
center of the cover.

133. Installation of Pressure Plate on Pressure Plate Cover

Slide a pressure plate return clip in place under each clutch lever
on the pressure plate cover. Place the cover in a press, blocking it up
as shown in figure 83. Place a wood block 2i^ inches square on top
of the clutch levers, and depress the levers (fig. 83) . Install the three
clutch adjusting screws, pressure plate return clips, lock nuts, and flat
washers in the pressure plate.

106

^Od(, 2'A *NC^«S SQUA«g

PIATC, PRESSURE
W/COV^ ~ 7372^64

RAJ»D 357898
Figure 83. Pressure plate Mocked up in precis for disassembling or assembling.

134. Adjustment of Pressure Plate

Install the clutch disk and pressure plate onto the flywheel (par. 86) .
Hold a straightedge across and against the edges of 2 clutch levers
where the release bearing normally makes contact. Turn the adjust-
ing screws until a distance of 27^2 inch is established between the
straightedge and the face of the pressure plate cover. When adjust-
ment is completed, hold the adjusting screws and tighten the lock nuts,
using wrenches. Hold straightedge across and against the edge of the
unadjusted lever and one which is adjusted. Turn adjusting screw
until 2%2 inch is established and tighten lock nut. Check previous
adjustment.

107

SPRING, ClUTCH PRESSURE ^WO-649975

TESTER ™ 4 M- 1600

RAPD 35789«
Figure S//. Making compression test on clutch pressure spring.

108

CHAPTER 6

ENGINE VENTILATION FOR DEEP WATER FORDING

OPERATION

Section I. DESCRIPTION AND DATA

135. Description of Underwater Ventilation System

(%• 4)

Operation of the vehicle underwater is made possible by the sealing,
at time of manufacture, of all parts or assemblies which are affected
immediately by the entrance of water. Watertight housings are
provided as standard equipment for all instruments, switches, starter^
generator, regulator, battery vents, ignition filter, and distributor, in-
cluding cables. The majority of these parts require venting to at-
mospheric pressure either to operate or to prevent damage due to
condensation. A series of ventilating lines, which are shown in figure
4, are provided for this purpose.

136. Carburetor Float Chamber Vent

The carburetor float chamber is vented to the air horn by an internal
passage and is extended to the air intake pipe by an external line, F.

137. Brake Master Cylinder Vent

(fig. 4)

The brake master cylinder is vented through line E which extends
up between the foot pedals to dash elbow D, mounted on the dash, and
line C to dash tee Q, and line P to air cleaner.

138. Fuel Tank Vent

(%. 4)

The fuel tank is vented through line B, which connects to the air
cleaner.

953383—51 8 109

139. Transmission, Transfer Vent

The transmission and transfer are vented through line N connected
to the top of the transfer to the air cleaner through dash tee Q and

140. Distributor Housing Vent

(%• 4)

Positive circulation of air through the distributor housing is as-
sured through lines L and M. One tube from the air cleaner L, pro-
vides an air intake for the venting ; the other, M, is connected to tee H
in the windshield wiper vacuum line. This vacuum connection pro-
vides positive ventilation and will draw off any water which might
possibly enter or collect in the distributor.

141. Crankcase Ventilation

(fig. 4)

The standard crankcase oil filler tube is used to ventilate the engine.
Air circulates from the air intake pipe into the oil filler tube and
►crankcase through line K. Circulation is completed through crank-
case vent outlet line J and a ventilating valve mounted in the intake
manifold. Ventilating control valves G, which are operated from
the instrument panel, are provided to block off the system when the
vehicle is submerged. This causes a pressure to build up in the crank-
case, thus preventing the entrance of water.

Section If. INSPECTION AND REPAIR OF ENGINE VENTILATION

SYSTEM

Caution: It is important that all personnel servicing the vehicle
understand the importance of using extreme caution and care when
making adjustments and replacements to guard against inadvertently
leaving vent lines or hose connections loose. Check all rubber hoses
for leakage due to deterioration. When replacing tubes, use sealer
as a safeguard against leakage. Replace all air ventilating lines that
are broken, pinched, or distorted. Check all connection points to as-
sure airtight connections.

142. Crankshaft Rear Bearing Seal

The crankshaft seals must be checked periodically as they are wear-
ing parts and must be sufficiently tight to maintain the necessary crank-
case internal pressure to prevent entrance of water should the engine
be submerged. For information covering method of checking, see
"Crankcase Internal Pressure" in section III.

110

143. Rear Main Bearing Seal

If inspection of the rear main bearing seal indicates leakage of oil
or entrance of water, this seal must be replaced. To install a new seal
in the bearing cap„ first clean the groove, dip the seal in engine oil to
provide initial lubrication and insert it in the groove. Press it into
the groove until seated and be sure that it is centered to allow from
0.020 to 0.030 inch to extend above the face of the cap at each side to
allow this amount of crush when the cap is installed. The same pro-
cedure should be followed when installing a crankcase seal. The
rubber packings (fig, 72) , between the bearing cap and the case are
cut to a given length and will protrude approximately % inch from
the case (par. 81). When the oil pan is installed, it will force this
packing tightly into the holes and will effectively seal any opening
between the bearing cap and the crankcase.

Section III. TEST OF INTERNAL CRANKCASE PRESSURE

144. General

When the vehicle is submerged, water is prevented from entering
the engine by internal crankcase pressure which builds up due to seal-
ing the engine ventilating system by closing valves "G" figure 4 and
ventilated as shown in figure 84. The amount of internal pressure
which develops depends upon piston and ring fits and also upon the
amount of leakage by engine gaskets and especially through the crank-
shaft front and rear seals discussed in paragraph 143 of this manual.
Ordinarily, two pounds pressure will prevent the entrance of water.

145. Lack of Pressure

Should pressure fail to build up, the fault may usually be traced to
leakage through the crankshaft seals, for they are subject to wear.
These should be checked periodically, for they may function perfectly
for highway use but fail when the vehicle is submerged.

146. Various Leakage Points

a. Gasket between the cylinder block and distributor.

&. Fuel pump gasket.

G. Timing gear cover gasket.

d. Valve cover plate gasket.

e. Crankcase ventilating line connections and gaskets.
/. Oil pan gasket.

g. Ventilating system ventilating control valves.

Ill

147. Internal Pressure Gage

A satisfactory gage may be readily made for checking internal
pressure. Secure a suitable pressure gage which must be calibrated
for low pressure. Install the gage on a spare oil filler tube cap with
the mounting airtight. To check the pressure, install the gage
mounted cap on the oil filler tube, using a gasket satisfactory for an
airtight mounting. Seal the crankcase ventilating system by pulling
out the control handle mounted on the instrument panel (fig. 86).
Start the engine and allow it to run until operating temperature is
reached (TM 9-804). If the engine is sufficiently tight to operate
satisfactorily when submerged, at least two pounds pressure will be
indicated on the gage.

VALVE CIOS5C

mm js7^u

Figure 85. Crankcase ventilation.

112

RA m 357926

Figure 86. Fording control valve plate.

113

Figure 87. ServiceaUlity standards points of measurement.

114

ftA Pl> 356014

Figure 88. i^crricca'bilitjj Htnndardi^ points of meamiremcnt.

115

Figure 89. ServiceaMUty standards points of measurement.

116

Figure 90. ServiceaMUty standards 'joints of measurement.

117

Figure 91. ServicealiUtv standards points of measurement.

Figure 92. ServiceaMlitp standards points of measurement.

118

^'AMAIXB. OF CIHiet
SiOl^ la CiNTit i^^

amz

Figure 93.

w^^ m cfmmm.

mm^m^l

ServiceaMlity standards points of measurement.

CAMSHAFT SUSPENDED AT POINTS A AND D

IN "V" BLOCKS ON SURFACE PUtE

MEASURED AT POINTS 8 AND C

RAPD 3$i022

Figure 94. ScrviceaMlity standards points of measurem^ent

120

CHAPTER 7
SERVICEABILITY STANDARDS

148. General

The serviceability standards listed in the following paragraphs give
the minimum, maximum, and key clearances of new or rebuilt parts
as well as wear limits which indicate that point to which a part or
parts may be worn before replacement, in order to receive maximum
service with minimum replacement. Normally, all parts which have
not been worn beyond the dimensions shown in the "Wear Limits"
column or damaged from corrosion will be approved for service. An
asterisk (*) in the "Wear Limits" column indicates that the part or
parts should be replaced when worn beyond the maximum size given
in the "Sizes and fits of new parts" column.

149. Cylinder Block

(par. 43)

(All dimensions in inches unless otherwise noted.)
a. Piston Bores.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new parts

Wear limits

Min.

Max.

F
B
B
K
K

Diameter at top of ring travel

Diameter at bottom of ring travel
Piston to block clearance.-

3. 125

0. 0021

3. 127

0. 0029

3. 137
3. 129
0.005

Rebore for next oversize at - _

0. 005

Max taper - _ - _

0.010

Out of round

0. 0003

0. 0005

0. 003

121

h. Valve Tappet Bores.

Fig. No.

Ref. Itr.

Sizes and fits of new parts

Wear limits

Min.

Max.

B
A

Dii

Ta
Re

imeter of tappet bore - -

O: 625
0. 0005

0.626
0.002

0. 6295

ppet to block clearance

■ 0. 003

bore for oversize at

0.003

c. Valve Seats.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new parts

Wear limits

Min.

Max.

J-K

Ive seat angle

45°

JVoie. Valve tappets are available in 0.004-tnch oversize.

1 50. Crankshaft

(pars. 69 and 83)

a. Crankshaet.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new
parts

Wear limits

Min.

Max.

88 -_

E
A

Run out — (Crankshaft sus-
pended at points
B& G).

End play

0.001

0.004

0.006

h. Main Bearing Journals.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new
parts

Wear limits

Min.

Max.

B-D-G

C
B-D-G
B-D-G
B-D-G

Diameter ^ _ -

2. 3335
0. 0005

2. 3340
0.001

2. 3330

Bearing to journal clearance- __
Regrind for next undersize at _

0.002
2. 3330

Max out of round. -

0.001

Max taper

0. 001

122

c. Connecting Rod Bearing Journals.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new-
parts

Min.

Ma.\.

Wear limits

Diameter

Bearing to journal clearance..
Regrind for next undersize at.

Max out of round

Max taper

1. 9372
0. 0005

1. 9377
0.001

1. 9367

0. 002

1. 9367
0.002
0.002

Note. Main bearings and connecting rod bearings are available in 0.010-, 0.020-, and 0.030-inch undersize.

151. Connecting Rod

(par. 50)

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new-
parts

Wear limits

Min.

Max,

F-H

Side clearance

0. 005

0. 009

0. 013

Allowable twist at 5 inches _

0.004

Allowable bend_

0.002

152. Pistons and Rings

(pars. 50, 51, and 53)

a. Pistons.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new
parts

Wear limits

Min.

Max.

86
58

I ^

Diameter of piston at top of
skirt (90 deg to piston pin) „ _

Diameter of piston at bottom
of skirt (90 deg to piston pin) _

Piston to block clearance

3. 1245

3. 1245
0. 0021

3. 1255

3. 1255
0. 0029

0. 005

123

&. Rings.

Sizes and fits of new

parts

Fig. No.

Bef. Ur.

Point of measurement

Wear limits

Min.

Max.

D-J

Thickness of compression rings
(2).

0.093

0. 0935

Thickness of oil ring (1)

0. 186

0. 1865

Top ring to groove clearance___

0.002

0.004

0.005

Center ring to groove clearance _

0. 0015

0. 0035

0. 0045

Bottom ring to groove clear-

0. 0015

0.004

0. 0045

ance.

Ring gap in cylinder block

0.008

0.013

0.020

c. Piston Pin Bores.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new
parts

Wear limits

Min.

Max.

A
A

Diameter __

0. 8120
0. 8150

0. 0001

0. 8122
0. 8152

0. 0005

0. 8137

Ream for 0.003-inch oversize

pin to.
Pin to piston clearance

0. 8167
0.001

Note: Pistons and rings are available in 0.020, 0.030, and 0. 040-Inch oversize.

153. Piston Pin

(pars. 50 and 52)

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new
parts

Wear limits

Min.

Max.

G
E

Diameter _

0.8117
0. 0001

0.8119
0. 0005

Pin to piston clearance

0.001

JVtrftf.— Piston pins are available in 0.003-ineh oversize.

124

154. Camshaft

(par. 55)

a. Camshapt.

Fig. No.

Ref. Itr.

Point 0/ measurement

Sizes and fits of new
parts

Wear limits

Min.

Max.

B-C
A

Run out „

0.001

Camshaft gear to thrust plate
clearance.

0.004

0.007

0.004

J). Bearing Journal Diameters.

Fig. No.

89
92

Ref. Itr.

Point of measurement

Front

Front intermediate
Rear intermediate.
Rear

Sizes and fits of new
parts

Min.

Max.

2. 186
2. 125
2. 0625
1.625

2. 1855
2. 126
2. 0635
1.626

Wear limits

2. 182
2. 121
2. 0585
1.621

c. Bearing to Journal Clearances.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new
parts

Wear limits

Min.

Max.

B
B
E
H

Front- __ __-_,_ -

0.001
0. 0025
0.002

0. 0025
0. 0045
a 0035

0.004

Front Intermediate - _

0. 004

Rear intermediate

0. 004

Rear

958383—5] — -i)

125

155. Intake Valve

(par. 59)

a. Valves .

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new
parts

Wear limits

Min.

Max.

Seat angle

45 deg _
0.373

Diameter stem _

0. 3623
0.116

0. 3608

Valve to tappet clearance

&. Valve Gtjides.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new-
parts

Wear limits

Min.

Max.

L
P
M

Inside diameter

0. 3745
0. 0015
0. 0565

0. 3755
0. 0132
0. 6575

0. 3785

Valve to guide clearance

Outside diameter ^ , _

0. 0192

c. Valve Tappets.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new
parts

Wear limns

Min.

Max.

B
F
A

Diameter.^

0. 6240
0. 0005

0. 6245
0-002

0. 6236

92
90
92

Tappet to cylinder block clear-
ance.

0.003

126

156. Exhaust Valve

(par. 59)

a. Valves.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new
parts

Wear limits

Min.

Max.

J
G
C
D

Seat angle __

45°
0.371

90 ..

Diameter stem

0.372
0.016
0.004

0. 3685

Valve cap to tappet clearance

90_„.

Valve to valve cap clearance---

0.000

0.005

&. Valve Guides.

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits of new-
parts

Wear limits

Min.

Max.

H
E
F

Inside diameter

0. 3745
0. 0025
0. 6565

0. 3755
0. 0045
0. 6575

0. 3785

90
90

Valve to guide clearence

Outside diameter

0.010

c. Valve Tappets.

Fig. No.

Ref. Itr.

Point of measuoemet

Sizes and flts of new
parts

Wear limits

Min.

Max.

Diameter .

0. 6240
0. 0005

0. 6245
0.002

0. 6285

Tappet to cylinder block clear-
ance.

0.003

127

157. Oil Pump

(par. 66)

Fig. No.

Ref. Itr.

Point of measurement

Sizes and fits ol new-
parts

Wear limits

Min.

Max.

91
65
91
66
91

A-B

C-D

E
F

Outer rotor lobe to inner rotor

lobe clearance.
Outer rotor to pump body

clearance.
Free length of plunger springs.

0.006
0.009

0. 0005
0.005

1. 8594

0.010
0.012

Plunger spring length when
load of V/i lb applied.

1. 0625

128

APPENDIX

REFERENCES

1. Publication Indexes

The following publication indexes and lists of current issue should
be consulted frequently for latest changes or revisions of references
given in this appendix and for new publications relating to materiel
covered in this manual :

Index of Administrative Publications SB 310-20-5

Army Regulations, Special Regulations, Readjustment Regulations,
Joint Army-Air Force Adjustment Regulations, General Orders,
Bulletins, Circulars, Commercial Traffic Bulletins, Joint Procure-
ment Circulars, Department of the Army Pamphlets, and ASF
Manuals.

Index of Army Motion Pictures and Film Strips SR 110- 1-1

Index of Army Training Publications SR 810-20-3

Field Manuals, Training Circulars, Firing Tables and Charts, Army
Training Programs, Mobilization Training Programs, Graphic
Training Aids, Joint Army- Navy Air Force Publications, and Com-
bined Communications Board Publications.
Index of Blank Forms and Army Personnel Classification

Tests SR 310-20-6

Index of Technical Manuals SR 310-20-4

Technical Regulations, Technical Bulletins, Supply Bulletins,
Lubrication Orders, Modification Work Orders, Tables of Organi-
zation and Equipment, Reduction Tables, Tables of Allowances,
Tables of Organization, and Tables of Equipment.

Introduction and Index (supply catalogs) ORD 1

Military Training Aids FM 21-8

Ordnance Major Items and Combinations and Pertinent Publi-
cations SB 9-1

2. Supply Catologs

The following catalogs of the Department of the Army Supply
Catalog pertain to this materiel :

a. Maintenance and Repair.
Cleaners, Preservatives, Lubricants, Recoil Fluids, Special Oils, and

Related Maintenance Materials ORD 8 SNL K-1

129

Items of Soldering, Metallizing, Brazing and Welding Materials:
Gases and Eelated Items ORD 3 SNL K-2

Lubricating Equipment, Accessories and Related Dispensers

ORD (*) SNL K-3
Tool-sets (common), Specialists' and Organizational

ORD 6 SNL G-27, Sec 2
h. Vehicle.
Truck, 14-Ton, 4x4, Utility, M38 ORD (*) SNL G-740

3. Forms

The following forms are applicable to this materiel :
WD AGO Form 9-71, Locator and Inventory Control Card
WD AGO Form 9-72, Ordnance Stock Record Card
WD AGO Form 9-76, Request for Work Order
WD AGO Form 9-77, Job Order Register
WD AGO Form 9-78, Job Order
DA AGO Form 9-79, Parts Requisition
WD AGO Form 9-80, Job Order File

WD AGO Form 9-81, Exchange Part or Unit Identification Tag
DA AGO Form 461-5, Limited Technical Inspection
DA AGO Form 468, Unsatisfactory Equipment Report
WD AGO Form 865, Work Order
WD AGO Form 866, Consolidation of Parts
WD AGO Form 867, Status of Modification Work Order
DD Form 6, Report of Damaged or Improper Shipment

4. Other Publications

The following explanatory publications contain information perti-
nent to this materiel and associated equipment :

a. Camouflage.

Camouflage — TM 6-267

Camouflage, Basic Principles FM 5-20

Camouflage of Vehicles FM 5-20B

h. Decontamination.

Decontamination TM 3-220

Defense Against Chemical Attack FM 21^0

c. Demolition To Prevent Enemy Use.

Ammunition, General TM 9-1900

Explosives and Demolitions FM 5-25

Qualification in Arms and Ammunition Training

Allowances AR 775-10

Regulations for Firing Ammunition for Training, Target Practice,

and Combat SR 385-^10-1

*See ORD 1, Introduction and Index, for published catalogs of the 0rdna,nce section
of the Department of the Army Supply Catalog.

130

d. General.

Cooling Systems: Vehicles and Powdered Ground Equipment

TM 9^2858

Fuels and Carburetion TM 10-550

Ordnance Service in the Field FM ^~f>

Precautions in Handling Gasoline AR 850-20

Principles of Automotive Vehicles -- TM 9-2700

Storage Batteries, Lead-Acid Type TM 9-2857

e. Maintenance and Repair.

Cleaning, Preserving, Sealing, and Related Materials Issued for
Ordnance Materiel TM 9-850

Hand, Measuring, and Power Tools TM 10-590

Instruction Guide: Welding Theory and Application TM 9-2852

Lubrication TM 9-2835

Maintenance and Care of Hand Tools TM 9-867

Maintenance of Supplies and Equipment : Maintenance Responsibili-
ties and Shop Operation AR 750-5

Motor Vehicle Inspection and Preventive Maintenance Services

TM 37-2810

Ordnance Maintenance : Carburetors (Carter) TM 9-1826A

Ordnance Maintenance : Electrical Equipment (Auto-Lite)

TM 9-1825B

Ordnance Maintenance: Fuel Pumps TM 9-1828A

Ordnance Maintenance : Vehicular Maintenance Equipment : Grind-
ing, Boring, Valve Reseating Machines and Lathes— TM 9-1834 A

Painting Instructions for Field Use TM 9-2861

Uneconomically Repairable Ordnance Vehicles SR 755-105-5

/. Operation.

i/i-Ton, 4 X 4, Utility Truck TM 9-804

g. Shipment and Standbt or Long Term Storage.

Army Marking Directive TM 38-414

Army Shipping Document — TM 38-705

Instruction Guide : Ordnance Packaging and Shipping (Posts, Camps,
and Stations) TM 9-2864

Ordnance Storage and Shipment Chart— Group G— TB 9-OSSC-G
Protection of Ordnance General Supplies in Open Storage

TB ORD 379
Standards for Oversea Shipment and Domestic Issue of Ordnance
Materiel Other Than Ammunition and Army Aircraft

TB ORD 385

131

INDEX

Accelerator linkage: Paragraph Page

Connect 103 98

Disconnect 20/i 21

Accidents, field report 3c 2

Adjustments:

Accessories 104 98

Engine 106 98

Pressure plate 134 107

Valve clearance 80 86

Air cleaner:

Installation 118 102

Removal 20j 21

Assembly :

Connecting rods 51 62

Flywheel 73 83

Manifolds. 78 84

Oil pump , 67 78

Oil strainer . ^ 67 78

Pistons 52 71

Pressure plate 132, 133 106

Valve tappets 63 74

Water pu[rip 47 59

Block, cylinder {See Cylinder block)

Cables:

Clutch cable:

Connect 113 101

Disconnect - 20o 17

Hand brake cable:

Connect 113 101

Disconnect 20o 17

Throttle Control cable:

Connect 120 102

Disconnect 20/i 21

Camshaft and gear:

Cleaning 54 71

Inspection and repair 55 72

Installation 79 85

Removal 39 47

Serviceability standards 156 127

Camshaft bearings:

Serviceability standards 156 127

Carburetor:

Installation ^ 95 96

Removal 25 38

Choke control cable:

Connect 120 102

Disconnect. 20/i 21

132

Cleaning: Paragraph Page

Clutch pressure springs 131 105

Connecting rods 49 62

Crankshaft 68 81

Cylinder block 42 53

Cylinderhead 42 53

Flywheel 70 82

Manifolds 76 83

Oil pan 42 53

Oil pump 65 78

Oil strainer 65 78

Pistons 49 62

Pressure plate - . — 131 105

Valves 58 73

Valve tappets 60 74

Water pump 45 58

Clearances :

Crankshaft 82 88

Pistons -- 51 62

Valves -^ 59,80 73,86

Clutch:

Cleaning 131 105

Connect linkage 107 100

Data -- 128 104

Description 4, 127 3, 104

Disconnect linkage 20s 23

Inspection and repair 131 105

Clutch cable:

Connect 113 101

Disconnect 20o 22

Clutch disk:

Installation 86 91

Removal 34 43

Clutch pressure springs:

Cleaning 131 105

Inspection and repair 131 105

Installation 132 106

Removal 130 105

Compression ratio 18 16

Connecting rods:

Assembly 51 62

Bent or twisted 50 62

Cleaning 49 62

Disassembly 48 62

Inspection and repair 50 62

Installation 84 88

Removal 40 49

Serviceability standards 153 124

Crankshaft:

Cleaning 68 81

Clearance 82 88

End play 83 88

Fitting crankshaft to flywheel 74, 82 83,88

Inspection 69 81

Installation 81 86

133

Crankshaft— Continued Paragraph Page

Removal 41 52

Serviceability standards 152 123

Crankshaft bearings {See Main bearings)

Crankshaft pulley:

Installation 88 93

Removal 39 47

Cylinder block:

Cleaning 42 53

Inspection and repair 43c 54

Serviceability standards 151 123

Cylinder head:

Cleaning 42 53

Inspection and repair 43& 54

Installation 90 94

Removal 36 44

Damaged studs:

Replacement 43d 54

Deep-water fording {See Ventilation system)

Disassembly:

Connecting rods 48 62

Flywheel 74 83

Manifolds 75 83

Oil pump 64 76

Oil strainer 64 76

Pistons 48 62

Pressure plate 129, 130 104, 105

Valve tappets 62 74

Water pump 44 58

Distributor:

Installation 98 97

Removal 29 38

Dynamometer test 105 98

Electrical cables:

Connect 117 102

Disconnect 20k 22

Engine :

Cleaning (See Cleaning)

Data 5, 18 3, 16

Description 4 3

Electrical system, description 15 16

Final operations (after installation) 126 103

General 13 15

Installation in vehicle 111 101

Lubrication 14 15

Removal from vehicle 20 17

Run-in test '_ 106 98

Trouble shooting 11, 12 12

Ventilation system 16, 135 15, 109

Engine stay cable:

Connect 113 101

Disconnect -_._ 20o 22

Exhaust manifold (See Manifolds)

Exhaust valves (See Valves)

134

Paragraph Page

Expansion plugs 43 53

Fan:

Installation 99 97

Removal 30 40

Field and depot maintenance allocation 2 1

Field report of accidents _ 3 2

Filters: oil {See Oil filter)

Flywheel:

Assembly 73 83

Cleaning 70 82

Disassembly 72 83

Fitting crankshaft to flywheel 74 83

Inspection and repair 71 82

Installation 85 89

Pilot bearing 71 82

Removal 35 43

Timing marks 85 89

Floor pan :

Installation 116 102

Removal 201 22

Forms, records, and reports 3 2

Fuel pump:

Installation 97 96

Removal 26 38

Gap, spark plug 18 16

Gears:

Camshaft (See Camshaft gear)

Crankshaft {See Crankshaft gear)

Timing {See Crankshaft gear and Camshaft gear)
Generator:

Installation 100 97

Removal 27 38

Hand brake cable:

Connect 113 101

Disconnect 20o 22

Ignition timing 18, 87 16, 92

Inspection and repair:

Camshaft and gear 54 71

Clutch 131 105

Clutch pressure springs 131 105

Connecting rods 50 62

Crankshaft 69 81

Cylinder block 43c 54

Cylinder head 436 54

Flywheel 71 82

Manifolds 77 83

Oil pan 43o 53

Oilpump 66 78

Oil strainer 65 78

Pistons 50 62

Pressure plate 131 105

Valve guides 43/ 56

135

Inspection and repair — Continued Paragraph Page

Valves 59 73

Valve springs S9 73

Valve tappets 61 74

Water pump 46 58

Installation:

Air cleaner 118 102

Camshaft and gear 79 85

Carburetor i^5 96

Clutch disk 86 91

Connecting rods _ 84 88

Crankshaft 81 86

Cylinderhead 90 94

Distributor 98 97

Engine HI 101

Fan 99 97

Flywheel 85 89

Fuel pump 97 96

Generator 100 97

Manifolds 91 95

Oil filter 97 96

Oil pan 89 94

Oil pump 67,92 78,95

Oil strainer 67 78

Pistons 84 88

Radiator 110, 122, 123, 124 101,

103

Starter 101 97

Thermostat 93 96

Transfer 104 98

Transmission 108, 112 100,

101

Valves 79 85

Water pump 94 96

Intake manifold (See Manifolds)

Intake valves (See Valves)

Main bearings:

Serviceability standards 152 123

Manifolds :

Assembly 78 84

Cleaning 76 83

Disassembly 75 83

Inspection and repair 77 83

Installation 91 95

Removal 32 43

Oil filter:

Installation 97 96

Removal 28 38

Oil pan :

Cleaning 42 53

Inspection and repair 43a 53

Installation 89 94

Removal 38 47

136

Oil pump: Paragraph Page

Assembly 67 78

Cleaning 65 78

Clearances 66, 67 78

Disassembly 64 76

Inspection and repair 66 78

Installation . 67,92 78,95

Removal 64 76

Serviceability standards 160 121

Oil strainer:

Assembly 67 78

Cleaning 65 78

Disassembly 64 76

Inspection and repair 65 78

Installation 67 78

Removal 38,64 47,76

Parts, special tools and equipment:
Field and depot maintenance:

General 6 8

Parts --- 7 8

Special tools and equipment 8 8

Piston pins (See also, Pistons)

Serviceability standards 155 126

Piston rings {See also, Pistons)

Installation 53,84 71,88

Removal 48 62

Serviceability standards 154 125

Pistons :

Assembly 52 71

Checking clearance 51 62

Cleaning 49 62

Disassembly 48 62

Inspection and repair 50 62

Installation 84 88

Removal 40 49

Serviceability standards 154 125

Plugs, expansion 43 53

Power plant (See also, Engine)

General 17, 19 16

Installation in vehicle HI 1^1

Removal from vehicle 20 17

Pressure plate:

Adjustment 134 107

Assembly 132, 133 106

Disassembly 129, 130 104,

105

Installation 86 91

Removal 34 43

Propeller shafts :

Connect 115 102

Disconnect 20w( 22

Pumps :

Fuel (See Fuel pump)
Oil (See Oil pump)
Water (See Water pinnp)

137

Radiator: Paragraph Page

110, 122 101,

Installation \ 103

123, 124 103

Removal 22 30

Records {See Forms, Records, and Reports)

References Appendix 129

Removal :

Air cleaner — 20j 21

Camshaft and gear 39 40

Carburetor 25 38

Clutchdisk 34 43

Connectingrod 40 49

Crankshaft 41 52

Cylinder head 36 44

Distributor 29 38

Engine 20 17

Fan 30 40

Flywheel - 35 43

Fuel pump 26 38

Generator 27 38

Manifolds 32 43

Oil filter 28 38

Oil pan 38 47

Oil pump 64 76

Oil strainer 38 47

Pistons 40 49

Radiator 22 30

Starter 2? 30

Thermostat 33 43

Transfer 24 32

Transmission 24 32

Valves 37 44

Water pump 31 43

Repair (See Inspection and Repair)

Ring, piston (See Piston rings)

Rod, connecting (See Connecting rod)

Run-in test:

Preparation 105 98

Engine run-in test 106 98

Sending units;

Connect 121 103

Disconnect 20e 17

Serviceability standards:

Camshaft 156 127

Camshaft bearings 156 127

Connecting rods 153 124

Crankshaft 152 123

Cvlinder block 151 123

General 150 122

Main bearings 152 123

Oil pump 157 128

Piston pins 155 126

Piston rings 154 125

Pistons 154 125

138

Paragraph Page

Spark plug gap 18 16

Spark plugs and cables;

Installation 102 97

Removal 29 38

Special tools (See Parts, Special Tools and Equipment) .

Speedometer cable:

Connect 114 101

Disconnect 20n 22

Starter:

Installation 101 97

Removal 23 30

Studs:

Inspection, repair, and replacement 43d 54

Tests:

Accessories 104 98

Engine run-in 106 98

Ventilation system 144, 145, 146, 147 111,

112

Thermostat:

Installation 93 96

Removal 33 43

Throttle control cable:

Connect 120 102

Disconnect 20A 21

Timing gears (See also. Crankshaft gear and camshaft gear).

Ignition timing 87 92

Timing marks 87 92

Torque specifications 148, 149 121

Transfer:

Installation 109 100

Removal 24 32

Transmission :

Installation 108, 112 100,

101

Removal 24 32

Trouble shooting:

Engine 12 12

General instructions and procedures 10, 11 1 1, 12

Purpose 9 11

Unsatisfactory equipment or materiel, report Sd 2

Valve guides:

Removal 43/ 55

Inspection and repair 43/ 55

Installation 43/" 55

Valves:

Adjustment 80 86

Cleaning 58 73

Clearance ■ ^ .. 59 73

Events 18 16

Inspection and repair 59 73

Installation 79 85

Removal . 37 44

Rotator-type (exhaust) ^-- - 56,57 73

139

Valves — Cootinued Paraerapk Pate

ServiwMibiUty standwds 155 126

Stem-to-oap clearance (exhaust) 5S 73

Timing --- 18 1<5

Valve springB:

Inspection 59 73

Installation - - 79 86

Removal - - 37 44

Serviceability standards 159 121

Vaive tappets:

Assembly 63 74

Cleaning - - -- 60 74

Disassembly - - 62 74

Inspection and repair _-.--. 61 74

Ventilation system, deep-water fording:

Data. . ..136,137.138,139.140,141 109,

110

Description - 136 109

Inspection and repair » 142,143 110,

111

Test__ - 144,146,146,147 111,

112

Water pump:

Assembly - -- 47 59

Cleaning - ---^ *6 58

Disassembly 44 68

Inspection and repair ^ — 46 68

Inatallation ---. - — 94 96

Removal 31 48

140

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